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Vestas Wins Big 1.1 GW Order, Videoray Underwater Workhorses, Wind Draws Extended Environmental Reviews

The Uptime Wind Energy podcast provides in-depth discussions about the latest news and developments in the wind energy industry. In this episode, the hosts Allen Hall, Joel Saxum, and Philip Totaro dive into topics including Vestas’ record 1.1 GW turbine order for a project in New Mexico, proposed federal regulations to streamline environmental reviews for some renewable projects while excluding wind, and Avangrid’s failed acquisition of PNM Resources. They also discuss underwater drone technology from VideoRay used for offshore wind farm inspections. Throughout the wide-ranging conversation, the hosts analyze these stories and more with their engineering, project management, and industry expertise, offering listeners valuable insights into the wind sector. This episode exemplifies why Uptime Wind Energy is an essential listen for anyone interested in or working in the renewable energy field.

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!

VideoRay – https://videoray.com
Pardalote Consulting – https://www.pardaloteconsulting.com
Weather Guard Lightning Tech – www.weatherguardwind.com
Intelstor – https://www.intelstor.com

Uptime 197

Allen Hall: Phil, did you see that in Australia during a tennis tournament that they had a deadly snake appear on the court?

Philip Totaro: Yes. I know.

Allen Hall: Rosemary’s not here to defend herself, but, oh my gosh, she swears to me that when you walk around Australia, you’re not going to be attacked by a poisonous snake, and yet There it is, headline news in the United States, poisonous snake at turn, at tennis tournament.

So it was like the world’s most deadliest snake, whatever that snake is. Joel, do you know what that snake is? The world’s deadliest snake?

Joel Saxum: It was the second most, and it was like a brown. Some kind of pit, Viper Brown something. I don’t remember what it was.

Allen Hall: And there it was right in the middle of this to tennis tournament just sitting there.

Philip Totaro: Allen, you must not watch tennis that often because when they used to have the tournament in Miami before they moved it into the Hard Rock Stadium they used to have like lizards in invading the tennis courts and stuff like that. So yeah it’s not uncommon for that sort of thing to happen.

But lizards are nice. Most most of the time they won’t kill you.

Allen Hall: But in Australia, they totally will. Yeah, and we were watching you guys watch the Mike Rowe show? I like Mike Rowe. Dirty Jobs, there you go. And he was milking dangerous spiders, poisonous spiders. And the whole time, you got these massive spiders, and on the whole, I’m just watching this thinking, That’s what’s in Australia.

That’s what’s in Australia. Oh my god, that’s what’s in Australia. I, can I get that out of my head? That’s a dangerous place. Even though Rosemary swears it’s nice. I’m sure that it is. And Matthew Stead From Ping says the same thing, we’re gonna have to go, Joel. I hate to say it, but I’m not gonna be the first one to step off the airplane.

I’m gonna have someone go ahead of me. So my

Joel Saxum: brother lives in Alaska, and he told me this one time, he said, You don’t have to be the fastest one, you just gotta be faster than your buddy.

Allen Hall: Australia has become a renewable energy center. Of course, Rosemary points out that they’re full of solar, and they have Essentially a renewable energy grid at this point.

But the wind industry is growing out there. There’s been a lot of movement out that way. And I hope Vestas installs a plant out there. And this episode we’re talking about the advancement of Vestas where they had a huge project announcement and expanding their factories in Colorado. So this is going to be interesting because.

As Phil has pointed out, Vestas is making a move and it is big, so stay tuned.

Vestas have received its largest order ever in the U. S. market, 1. 1 gigawatts of turbines, which is about 242 turbines of the V163 4. 5 megawatt machines. That that are going to be built in Colorado for Pattern Energy’s Sunzea Wind Project in New Mexico, so right next door to Colorado. The turbines won’t have very far to go.

It is the largest order onshore for Vestas ever. It includes all the supply, delivery, and commissioning of the turbines and a, as Vestas has proven out, a multi year service agreement. So everybody around Pattern and Vestas is super happy. You remember Vestas had put some money in about 40 million into the two factories in Colorado, one’s a blade factory, one’s in a cell factory to expand them for this particular product line.

So this is working out for Vestas quite lovely at the moment, Joel. It seems the 4. 5 is going to be a pretty useful machine as the repowering efforts and new projects are developed in the United States.

Joel Saxum: Yeah New Mexico is a fantastic place to put a lot of these out too, right? Because where this project is sited at is It’s very rural.

It’s wide open spaces. It’s just if you’re familiar with looking at West Texas, it’s an extension of West Texas, basically. So these are some big turbines, right? These are the ones that you see from even a long ways away and say, wow, that thing is freaking massive. They’re going to have an 80 or that 163 meter rotor on them.

They’re going to have an 80 meter blade or a 79 meter blade on them. So they’re going to be some big machines. But the whole project here is the interesting thing. Because Sun Zia has been, that idea of a project has been around for a long time and that was always focused on the transmission part of it, right?

It was bringing this power from this idea of this development over towards Phoenix, crossing to Arizona and to feed that southwestern portion of the United States. And to me, I guess it was, maybe I wasn’t thinking correctly or whatnot, and suddenly they were like, Hey, Sun Z is good to go. Also, 1.

order with it. Congrats to Vestas and Pattern, really, for putting this thing together and finally getting it across the finish

Allen Hall: line. Phil, this is a big project for Pattern, isn’t it? Yeah, it’s

Philip Totaro: part of a 3. 5 plus gigawatt project. They’re spending 11 billion dollars on the entire thing, including the transmission.

Also went under the radar last week after Vestas made their announcement was that GE also made their announcement that They’re also going to be supplying some turbines. I don’t, actually, it’s funny because I don’t know if it’s actually for the rest of it the remaining 2.

4 gigawatts or not but there are three phases of this project, so it’s potential that Pattern may also want to or has yet to announce and explore a relationship with Siemens Gamesa or Nordex on that. If that’s what they’re doing, but in the meantime, yeah this entire project is it’s gonna be probably the biggest a onshore multi phase project outside of China China, there are places in.

there are Various deserts there where they’re doing something similar, they’re setting up just massive arrays of turbines and solar panels and everything. Outside of China, this is going to be the biggest onshore project in the country, certainly the country and the rest of the world.

So

Joel Saxum: Allen, I want to ask you a question on this one. Now, of course we can, from the armchair, we can sit and say, okay, this is going to be a three, three and a half gigawatt project. That’s crazy, right? The largest single phase installation in the U S is about one gigawatt. So this is three times. Of course it’s multi phase.

But we know that you probably can’t turn to Vestas and say, Hey, we need 700 V1 63s in the next 18 months. They’re not going to be able to do it. So we know that you need to probably, like you said, Phil, get some GE turbines in there, get some Vestas turbines in there. There might even be some other suppliers thrown in there.

So we know that’s just a reality from the supply chain standpoint. But on an engineering side, what does that do for the project?

Allen Hall: Holy hell it’s gonna be a big, complicated project, right? Here’s my concern about this whole project is, you’re putting all your money on the table, and you’re spinning that wheel.

A lot of these turbines haven’t been that well examined, right? And, yeah, and New Mexico’s a tough place. That’s what worries me. A lot of lightning, a lot of everything in New Mexico. The winds are strong, right? That’s why they’re there. You gotta wonder if something were to be bad on the turbine, boy, it would just explode.

This is the Siemens energy problem, right?

Joel Saxum: Man, yeah, it’s a complicated geographically, right? Because you have mountain mountains to the south in Mexico you have mountains that subtend the middle of Or the western side of this project in the middle of New Mexico And then you have that hot weather going off to the plains like it’s a complicated weather area as well strong winds Of course, that’s fantastic for the wind industry.

We deal with that all the time But also the tendency for microbursts and hail and really strong convective storms in that area.

Allen Hall: Yeah, the weather there is not great. The winds are good, but the big storms hit that part of New Mexico and that worries me. There’s just a lot of unknowns here. I would feel a lot more comfortable if this ended up in Oklahoma or Kansas or even Iowa, some places that we have a better understanding of.

Something this big in New Mexico. I don’t know

Joel Saxum: if we’ve been there before. I do think that the size of this wind farm complex, we’ll call it, has the ability to literally fuel an entire town. You’re gonna If you’re gonna have 700 some odd massive turbines, the workforce that’s going to be needed, you’re gonna need a hundred people out there regularly working on the thing that’s gonna, that are gonna be permanent residents of this area, which is a very rural area.

New Mexico is challenged For rural development and and job. So this is, it’s going to be a boon to that corner.

Allen Hall: To Phil, does this make sense in terms of the proximity? Is that part of it, of the Vestas production plants being pretty close and the tower plants are right there in Pueblo, I’m assuming.

So they’re not very far from the border of New Mexico. Is it a. Closeness that’s playing into the, to the part of this transaction that, that the factory is right up the street. Part of it,

Philip Totaro: certainly. And keep in mind that Vestas obviously sold the tower manufacturing to CS Wind and CS Wind actually just released some new projections, financial projections based on presumably the fact that they’re getting, a lot of these and other of the Vestas turbine orders.

Vestas now has, I believe, something on the order of 3 to 3. 5 or 3. 6 gigawatts worth of V163 orders now globally. Which is great for that platform. Although, like you say part of it’s unproven, certainly the blade is a new blade. It’s based on their pre existing technology, but it’s not a product that’s been out there.

GE, my understanding is that they’re going to be using the 2. 8 127s and, 2. 3 to 2. 5, 116s. Nothing that hasn’t been previously experienced there again, the question is would a company like Pattern Energy take a punt on the Nordex N 155 or N 163 or are they gonna, I don’t know what happens with Siemens Gamesa, if they’re going to be prepared to start supplying turbines.

Now that we’re in 2024, happy new year, everybody we’re, are, is Siemens Gamesa going to start selling and supplying turbines again this year for delivery later this year and into next year, which is that project is going to be under construction for. They got a lot to, they got a lot to build.

Allen Hall: Phil, there’s two pieces to this that I’m trying to learn about. One is how fast is Vestas going to try to produce those turbines? Are they really going to try to ramp up these factories with the 40 million they’ve invested in? To then rapidly turn around these turbines, or they can try to spread it out.

One, two, Siemens is in trouble. If they’re not able to get into some of these bigger projects, particularly on shore, which is a strength for them or has been historically. Does Vestas, which is looking very aggressive at the moment, really push Siemens out of the U. S. market, or try to, and then shove their way into that broader North American, South American marketplace?

Philip Totaro: If that, if the latter happens, Allen, what happens is Nordex basically takes over the number three spot in terms of U. S. wind turbine OEMs. So that would be interesting, but Nordex doesn’t have necessarily as competitive of a product offering it’s it, look at whatever metric you want the, Megawatt hours produced, the capacity factors, the and some of it is, they’re unfortunately disadvantaged by not having access to the best project sites, so they can’t really shine.

There’s nothing necessarily inherently wrong with the N149 or the N155 or 163 product platform. It’s actually a pretty solid product. But again that’s part of the issue is they’ve never really They’ve never even if Vestas starts taking business away from Siemens, and orders away from Siemens Gamesa, does that necessarily allow somebody like Nordex to flourish, or does it open up?

Is it just gonna be a knockdown drag out between GE then, a bunch of other small players also want to domesticate production in the United States. Does this open the door for them if they’re willing to come in and spend money? That’s, it’s a complicated, that’s a very complicated thing.

The other aspect of this, going back to your earlier question, was Yes, the proximity for the Vestas factories plays into them getting the supply, but also with these 45 X manufacturing tax credits that are providing a domestic content bonus, shall we say for domestic sourcing of some of the components.

That’s going to do a lot of good things both for Vestas and for Pattern because they’re going to be getting a pretty you’re talking about what, about, 550, 000 per turbine if they domestically source all the components that they can under that, that tax credit program.

So that’s a pretty decent chunk of the cost of the

Allen Hall: turbine. I want to. Tie in the Nordex piece because they did sign that extension with Eris down in Brazil to make blades down there. I’m wondering if that’s their fallback position, is to crank up Eris to make blades if they want to start going after some Siemens projects.

Philip Totaro: They’re, they have enough orders in Brazil and in adjacent markets in South America that the Eris thing is good. The question is, will Eris come, cause Eris has been talking about wanting to come to the U. S., now that we have this proposed regulations for the 45 X manufacturing tax credit. I wonder if that doesn’t, I think we’re going to see, for instance, I was mentioning this before off air, like companies like NGC with making your boxes in China, anybody.

That G. E. Vestas, Siemens Gamesa, or Nordex is using that’s a foreign company is going to want or probably need to domesticate some of their production capacity in the U. S. So that these companies can take advantage of it, because one of the provisions of this is that you can’t just import foreign made goods and just assemble it.

That doesn’t qualify fully for That bonus, tax credit. So the question here is, does Ares, does this relationship that Nordex and Ares have in Brazil, does that then help facilitate the relocation of Ares to, set up a factory in the U S either

Joel Saxum: way. I think that there’s an interesting play here.

Like Phil, you’re talking, we’re talking about market share with Siemens and all these different things. In the last I don’t know, man, two weeks, up until the end of the year, it was like Vestas, watching LinkedIn, it was like Vestas had held all of their cards right until the end of the year, and they were like, Order for 400 gigawatts, order for 1.

1 400 megawatts, Boom. they do That, though. they Always announce, like, all their orders in bulk, at the end of every quarter, financial quarter. But this was actually, they they announced a total of 17 gigawatts, but it wasn’t all Firm Orders, it was something like 12.

Philip Totaro: 8 gigawatts of Firm Orders and then the rest of it was all preferred supplier and conditional orders. But it was still, it’s a huge order haul. And again with some degree of certainty, again, they haven’t finalized these 45x tax credit rules in the U. S.

And we don’t know what the profitability of some of these orders is for places in South Korea and throughout Europe with some of these offshore orders, but this is, it’s still a big deal. That’s a lot of orders to be able to announce in one quarter. And if you go back to November the CEO was basically hinting at the fact that they were going to drop all these orders, and it was going to be a big end of the year and

Joel Saxum: it turned out to be.

The interesting take from this whole thing that we’ve been talking about here for the last ten minutes is the fact that the IRA bill, as designed, A year and a half ago, is starting to do its job.

Allen Hall: Is it? Or the Treasury Department doing it?

Joel Saxum: To be, like, like Phil was saying, if you’re using an NGC type deer box or someone from China, there it’s, will force them to be competitive, it’ll force them to do some manufacturing in the United States.

That was the point of the IRA Bill in

Allen Hall: general. Yeah, I’m still a little dubious, because the time frame is too short. so if you’re Trying to build a factory in the United States and get up and running, that’s going to take two years minimum, especially for something that’s complicated as NGC.

So The chances of that happening, I think, are small. It’s going to be those that already have factories in place, like Vestas or GE, that could easily spool up something pretty quick.

Philip Totaro: Yes and no, because like I mentioned before, if they’re already qualified for the 48C manufacturing tax credit from a previous PTC authorization.

They can’t double dip on the 45X. This, the 45X and the IRA bill is intended to facilitate new build factories in the United States. The question though is, there these credits go until 2030. At the current rates that they have. And it, again, it works out to be about 120, 000 per megawatt for an onshore turbine, 140, 000 per megawatt for an fixed bottom offshore turbine, and 160, 000 per megawatt for a floating offshore turbine, however.

As Allen just mentioned, you’re talking about a scenario where it’s going to take, I’ll give them the benefit of the doubt and say 18 months, but you’re talking about a timeframe where you’re not even really able to pull the trigger because they took so much time to clarify these regulations and they’re still not even finalized yet.

Now we’re losing opportunity and we’re losing momentum on being able to take advantage of the domestication of the. Manufacturing facilities. The other question is, if this only really runs out to 2030 and then starts ramping down, and by 2032, the 45x tax credits go away, How many companies are going to be able to secure enough of an order book to be able to justify the factory investment, because you’re talking about if you’re trying to do a, if you’re a gearbox vendor like NGC and you’re trying to domesticate production of everything that, that, GE is going to need from you and keep in mind that NGC is not their only vendor, but you’re going to you’re going to need at least.

like Three gigawatts worth of orders to be able to pull the trigger on what is going to end up being like a three hundred to four hundred million dollar factory, give or

Allen Hall: take. that’s the Problem. But if somebody is looking to put U. S. content, and I do know of a company that’s based in the United States that manufactures parts for wind energy.

That’d be Weathergard, Lightning Tech, we’re in Massachusetts and we make the thing here. That’s right. Someone Can actually pick up the phone and call us because we’re it. We’re probably one of the few that actually is a vast majority. I wouldn’t say a hundred percent, but it’s damn close to it. U. S.

content. We’re easy. I know we’re s only we’re small. But still. That’s a good plug. Come on, Phil. Does it include Intel

Philip Totaro: Store, too? we Provide digital services any anywhere in the world. Doesn’t that

Joel Saxum: count? Phil is manufacturing insights from the data.

Allen Hall: Hey, uptime listeners. We know how difficult it is to keep track of the wind industry.

That’s why we read P. E. S. Wind Magazine. PES Wind doesn’t summarize the news. It digs into the tough issues, and PES Wind is written by the experts. So you can get the in-depth info you need. Check out the wind industry’s leading trade publication, PES wind@pswind.com.

Joel Saxum: So one of the things I talk about on the podcast fairly regularly is offshore wind operations because it’s a mystery. if You’re, looking at an onshore wind farm, or if you’ve been in oil and gas, you’ve been in construction industry, you’ve seen people build highways, these are massive infrastructure projects, but you see what’s going on.

You see a dozer driving, or a surveyor out there, or some people moving drainage stuff around, you can see all of that. But when you get to offshore wind, you can’t see any of that. You see a couple of vessels on the surface driving around, but you cannot see anything that’s going on underneath them. And that’s where all the work is happening.

VideoRay is is a part of that solution. Now, they’re in PES Wind Magazine this, this quarter talking about off, offshore wind inspections. Now, They don’t just do inspections with their equipment on the operation side. They do it during development, during construction and during operations.

So think of what a VideoRay offers as a solution being a basically a drone that you see in the air. Again, I’m trying to relate it to something everybody’s seen except for much more expensive and something that swims and swims sub C. The, it’s not, I’m not going to say it’s trivial to build a drone.

But it’s not super difficult. The concepts are pretty easy. Flying in air and communications and positioning is fairly easy compared to sub C because when you go sub C, you cannot communicate very well. You cannot position very well. Cameras are hard to use because contrary to popular belief, not everything sub C looks like the great barrier reef that’s beautiful and blue and clear.

So there’s a lot of. Technology that goes into these kits that they send subsea. So in the industry, they’re called ROVs. We think about them as remotely operated vehicles and VideoRay makes a couple of different models, but they’re in the inspection class. So there’s a couple of different ones.

There’s like your hobbyist that looks like a, a drone that’s smaller than you have the inspection class ROVs, which is what VideoRay makes. That are like 20 to 40 pounds or so, about the size of, I don’t know, like a cooler? Like a Yeti cooler or something like that? And then you go to the next level of things, which is like an intervention and work class ROVs.

Work class ROVs can be the size of a truck. they’re Freaking huge. but These pieces of kit that they have, they can do all kinds of things. They can inspect things visually. They can inspect with sonar. They can put manipulators, little hands on them. They can grab things off the floor. Or off the seafloor.

They can test with NDT probes. So you can check the thickness of metal. You can check cathodic protection on things, which is basically the kind of metal blocks you put subsea to combat the seawater and alkaline steel interact, or metal interactions. So they can do a lot of things. if you’re On an SOV offshore or on any kind of construction vessel, these Little ROVs are out there.

They’re watching rock dumps to make sure that they’re laying in the right place. They’re watching cable inspection. They’re doing cable inspections. They’re watching cable hookups. Sometimes the work class ROVs down there and the inspection class is standing off just to watch what they’re doing.

They’re mapping things. They can map rock dumps, map the surface of the floor. They can do visual inspections. They can create. 3D models of monopiles and, all kinds of things subsea, so they’re very powerful tools. I think that VideoRay’s got about 4, 000 of them. When I was in oil and gas, VideoRay was a company that you thought of all the time.

Hey, we gotta get this inspection class over. Yeah, grab one of those VideoRay. Boom, throw that on board. That was something we always used. They’re using the defense space, oil and gas, civil construction, everything offshore. Inspecting nuclear plants, all kinds of cool stuff. so Think of them as a drone in the sky, but underwater.

However, they’re much more advanced. VideoRay’s Starting to use AI to do station keeping and model building and inspections. Because if you’re driving down a pipeline with a ROV, you’re just going pipe joint, oop, little bit of free span there. It’s very monotonous and very manual for the operator to do, but with AI, now you can Automate a lot of those tools. The last bit I would say here, and this is a, an idea because we’re always looking for what could be better in the wind industry. What’s innovation. What’s cool. If I was inspection company that had people mobilized around the world with drones, inspecting blades, cells, transition pieces offshore, which are part of regular tenders now.

I would also start to include inspecting subsea at the same time. And here’s the reason. You’re already there, you already have specialized employees out there, and the vessel is standing by while you fly with the drone. You might as well throw the ROV overboard and do the subsea portion of the inspection at the same time.

Now you can deliver the client value add. So you’ve got an inspection from the tip of the blade all the way to the seafloor. And you’re using the same people and the same vessel time. And that’s the big thing that costs offshore. So if you want to do that as an inspection company, call me,

Philip Totaro: I’ll walk you through.

So it sounds like there could be some acquisitions in the the in remote inspection space there should be. And if

Joel Saxum: this is the big thing to if you’re a company that has a platform, that’s looking at assets that, you have like sky specs is the nice horizons platform or. Everybody at Perceptual Robotics has their platform and ZiteView has their platform and Thread has their platform.

You should be putting in a module in that to manage that subsea data at the same time. And

Allen Hall: if you want to stay abreast of all the cool technology pieces in the wind industry in 2024, you better get the Q4 edition of PES Wind from 2023 because it is full of cool technology and it has a lot about what’s about to happen.

So you’re going to see a lot of technology in PES Wind in this latest edition. You’ll see it out in the field, come up in a couple of months when it warms up, up in the Northern Hemisphere. So check it out. You can go to PESWind. com. You can get a free, download and you can read about all the things we, we talk about in the podcast.

back in November The Department of Energy proposed a rule to speed up environmental reviews for some renewable energy projects. The proposal would have, or does expand exclusions that allow faster review of projects with minimal environmental impacts. Now, there’s a number of projects or project types that would apply it here to solar arrays, power line upgrades, batteries, flywheel storage systems, things that are pretty much neutral in the environment and have shown years of history of doing such.

Thank you very much. The one item that is not in that list is wind turbines. And I think basically anything over 200 feet tall applies where you have to get the environmental impact done, even though that has been accomplished at this point, Joel, hundreds of times in the United States. And there really hasn’t been any issue, but they the DOE kept, the environmental reviews the way that they have been historically for wind projects.

And I think the wind industry has got to scratch their head about this because that was an opportunity to make the process simpler, and they decided not to do it. So they gave it to solar on some level, and they gave it to power lines, fine, just power lines. However, come on, let’s, what has wind energy done to deserve the this they should have been able to use the history of wind projects being cited and installed.

And they have years of data, 20 plus years really of data. Why would they not? Shorten the time period these environmental

Joel Saxum: reviews happen to me. It seems like there’s an easy way to do this, right? if you Have a categorization that you fall under certain citing rules and design rules, operational rules, if you fit in that box, you shouldn’t have to go for this extra.

different kind of DOE big play. I think that if you’re going to have intense rules, or if you want to really regulate something and it’s on say BLM land, like Bureau of Land Management, federal land or something of that sort, I can understand that’s public land that has public interest to it.

but if Private entities are building on private land, for the good of the environment or the, for the good of the public, I don’t see why there should be. Long queue lines and intense rules for that.

Allen Hall: Phil, does this make sense with everything else that’s happening in the DOE and the Treasury Department trying to speed up wind industry development and installation of wind turbines?

This is one of the roadblocks. Every time, for every project, this is one of the roadblocks. It just eats up a bunch of time.

Philip Totaro: And remember back to my infamous rant last year about, how all these projects based on that study that was done by, Columbia University, there’s, 45 states that have some kind of regulation on or restriction on wind and solar development.

And the fact that we’ve never had cohesive and unified federal policy that allows for a consistent permitting application review process, we’ve never had, with the exception of rules that have been established for, what’s done on public lands. but Again, that’s not a streamlined process like we’re talking about.

the fact that they Would streamline the process for other things but not wind, I really don’t get it. we’re Now six or approaching seven percent probably by the end of 2023 now of the domestic electricity production and generation in the United States. We’re still, at this point, bigger than solar, although they’re catching up quick, but what do we have to do?

Allen Hall: Yeah, I don’t know, I don’t understand why the DOE is not having this discussion internally or why someone over there didn’t say, hey. What about wind? It’s a political issue. That’s what, okay, that’s what I wanted to get to. The

Joel Saxum: problem is it’s a political issue because they’re visible and it’s a partisan issue.

Solar panels are visible? Yeah, it’s not a technical argument anymore. It’s a political argument and that’s the

Allen Hall: problem. So do you think it was left open because there’s a pushback because of the size of the turbines and some, at some point we can have another Ted Kennedy situation where a senator can just essentially stop it.

in their Backyard. is that what This is about? Because this is getting to be a little ridiculous. and if, but that Shouldn’t, that doesn’t prohibit states from blocking projects on their own, right? They totally can. And why wouldn’t they, right? But in, in places like, Texas, Oklahoma, Kansas, Iowa, Illinois, Indiana, where there is a process in place at the state level, what, and have, they have historical data that shows they can develop these projects without all these environmental reviews, then what are we doing?

It’s confusing to

Joel Saxum: me. It even goes farther than environmental reviews as well, because I read an article today that stated Avangrid was going to buy PNM and they backed out of it because PNM. Did not get regulatory approval of, for the acquisition.

Allen Hall: So is that what they anticipate that the feds would object to the acquisition?

And so they were just hedging their bets that it’s just going to take, or they just felt like it’s going to be a long time for the reviews to

Philip Totaro: go through. It’s already been, they’ve been working on this for four years or five years already. So

Allen Hall: is, does that mean that the Fed, at the federal level, it’s taking too long?

it’s been four or five Years and they haven’t gotten all the paperwork through that they needed to? Is that what that, what this all indicates? I

Philip Totaro: think there’s probably a backroom, there was a backroom discussion that was basically like, this isn’t gonna happen, so they pulled the plug.

Joel Saxum: And it’s, there’s articles, from June April, June, July of this year that are like, We, this is going to be, this is going to happen.

This is going to be fantastic. Merger is going to go through and then

Allen Hall: you go. What’s the objection here. It’s just the size of the project of the exchange. And the resulting company, is that what it is, or is it bigger than that? That’s some of these acquisitions and mergers, how they’re not getting through the SEC.

Joel Saxum: The article today was Reuters. Eberdrola’s Avangrid, so Avangrid terminates 8. 3 billion deal to buy PNM resources. They terminated it today. And there’s no reason given. It’s, it says, because it could not get all the necessary regulatory approvals to close the deal by December 31st. Wow. Delays it from the federal.

Probably FERC and someone else. A regulatory, what else would regulatory be in that SEC maybe? Sure,

Allen Hall: that would have to be a part of the review process, right? Just because of the size of the transaction and who’s involved and it’s an energy

Joel Saxum: transaction. The deal worth 4. 3 billion excluding debt was unanimously approved by PNM’s board in 2020 and was expected to create a renewable energy operator with a combined market value topping 20 billion.

There’s

Allen Hall: going to be a lot of transactions happening in the next 24 months from what I can tell. And if there’s going to be a regulatory hurdle, then a lot of them are going to be stuck. And that’s, this is not the time for that to happen. What would be the concern? I don’t. There’s been so many other transactions across the world at the moment in renewable energy, why that one?

Again, is it politics, Phil? yeah, part Of it, but that’s, was gonna be my point, is I could see them putting a kibosh on a deal if it was like a Chinese parent company was coming in and trying to buy something, but this is a Spanish company that’s a huge utility and basically the biggest, owner operator of renewable energy in the world.

Philip Totaro: So I don’t get it. They

Allen Hall: backed out a couple of offshore wind projects in the state of Massachusetts.

Philip Totaro: But they just released that report about how many jobs they created. everybody Should be excited. They created more union jobs than expected.

Allen Hall: There is a big discussion about that in the state of Massachusetts because it has maybe created some union jobs but it’s squished some non union jobs and there’s Port and the people around the port aren’t super happy because a lot of people coming from the outside that area More to come there.

I’m sure and I and you know the thing think same things happen in New York It’s going to happen in New Jersey is going to happen up and down the east coast of United States is they try to show jobs because this is, hey, welcome to 2024. There’s going to be 10 plus months of this as good paying union jobs.

How many times are you going to hear that in the next 10 months? That’s just part of it, right? That everybody’s trying to show their credentials that they have created union jobs for these offshore wind projects, whether they. Have or not, unclear. That’s going to do it for this week’s Uptime Wind Energy Podcast.

Thanks for listening. Please give us a five star rating on your podcast platform and subscribe in the show notes below to Uptime Tech News, our weekly newsletter. And check out Rosemary’s YouTube channel, Engineering with Rosie. We’ll see you here next week on the Uptime Wind Energy Podcast.

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Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage

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Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage

This exclusive article originally appeared in PES Wind 4 – 2025 with the title, Operations take center stage in wind’s next chapter. It was written by Allen Hall and other members of the WeatherGuard Lightning Tech team.

As aging fleets, shrinking margins, and new policies reshape the wind sector, wind energy operations are in the spotlight. The industry’s next chapter will be defined not by capacity growth, but by operational excellence, where integrated, predictive maintenance turns data into decisions and reliability into profit.

Wind farm operations are undergoing a fundamental transformation. After hosting hundreds of conversations on the Uptime Wind Energy Podcast, I’ve witnessed a clear pattern: the most successful operators are abandoning reactive maintenance in favor of integrated, predictive strategies. This shift isn’t just about adopting new technologies; it’s about fundamentally rethinking how we manage aging assets in an era of tightening margins and expanding responsibilities.

The evidence was overwhelming at this year’s SkySpecs Customer Forum, where representatives from over 75% of US installed wind capacity gathered to share experiences and strategies. The consensus was clear: those who integrate monitoring, inspection, and repair into a cohesive operational strategy are achieving dramatic improvements in reliability and profitability.

Takeaway: These options have been available to wind energy operations for years; now, adoption is critical.

Why traditional approaches to wind farm operations are failing

Today’s wind operators face an unprecedented convergence of challenges. Fleets installed during the 2010-2015 boom are aging in unexpected ways, revealing design vulnerabilities no one anticipated. Meanwhile, the support infrastructure is crumbling; spare parts have become scarce, OEM support is limited, and insurance companies are tightening coverage just when operators need them most.

The situation is particularly acute following recent policy changes. The One Big Beautiful Bill in the United States has fundamentally altered the economic landscape. PTC farming is no longer viable; turbines must run longer and more reliably than ever before. Engineering teams, already stretched thin, are being asked to manage not just wind assets but solar and battery storage as well. The old playbook simply doesn’t work anymore.

Consider the scope of just one challenge: polyester blade failures. During our podcast conversation with Edo Kuipers of We4Ce, we learned that an estimated 30,000 to 40,000 blades worldwide are experiencing root bushing issues. ‘After a while, blades are simply flying off,’ Kuipers explained. The financial impact of a single blade failure can exceed €300,000 when you factor in replacement costs, lost production, and crane mobilization. Yet innovative repair solutions, like the one developed by We4Ce and CNC Onsite, can address the same problem for €40,000 if caught early. This pattern repeats across every major component. Gearbox failures that once required complete replacement can now be predicted months in advance. Lightning damage that previously caused catastrophic failures can be prevented with inexpensive upgrades and real-time monitoring. All these solutions are based on the principle that predicted maintenance is better than an expensive surprise.

Seeing problems before they happeny, and potential risks

The transformation begins with visibility. Modern monitoring systems reveal problems that traditional methods miss entirely. Eric van Genuchten of Sensing360 shared an eye-opening statistic on our podcast: ‘In planetary gearbox failures, they get 90%, so there’s still 10% of failures they cannot detect.’ That missing 10% represents the catastrophic failures that destroy budgets and production targets. Advanced monitoring technologies are filling these gaps. Sensing360’s fiber optic sensors, for example, detect minute deformations in steel components, revealing load imbalances and fatigue progression invisible to traditional monitoring. ‘We integrate our sensors in steel and make rotating equipment smarter,’ van Genuchten explained.

Other companies are deploying acoustic systems to identify blade delamination, oil analysis for gearbox health, and electrical signature analysis for generator issues. Each technology adds a piece to the puzzle, but the real value comes from integration. The impact of load monitoring alone can be transformative.

As van Genuchten explained, ‘Twenty percent more loading on a gearbox or on a bearing is half of your life. The other way around, twenty percent less loading is double your life.’ With proper monitoring, operators can optimize load distribution across their fleet, extending component life while maximizing production.

But monitoring without action is just expensive data collection. The most successful operators are those who’ve learned to translate sensor data into operational decisions. This requires not just technology but organizational change, breaking down silos between monitoring, maintenance, and management teams.

In Wind Energy Operations, Early intervention makes the million-dollar difference

The economics of early intervention are compelling across every component type. The blade root bushing example from We4Ce illustrates this perfectly. With their solution, early detection means replacing just 24-30 bushings in about 24 hours of drilling work. Wait, and you’re looking at 60+ bushings and 60 hours of work. Early detection doesn’t just prevent catastrophic failure; it makes repairs faster, cheaper, and more reliable.

This principle extends throughout the turbine. Early-stage bearing damage can be addressed through targeted lubrication or minor adjustments. Incipient electrical issues can be resolved with cleaning or connection tightening. Small blade surface cracks can be repaired in a few hours before they propagate into structural damage requiring weeks of work.

Leading operators are implementing tiered response protocols based on monitoring data. Critical issues trigger immediate intervention. Developing problems are scheduled for the next maintenance window. Minor issues are monitored and addressed during routine service. This systematic approach reduces both emergency repairs and unnecessary maintenance, optimizing resource allocation across the fleet.

Turning information into action

While monitoring generates data, platforms like SkySpecs’ Horizon transform that data into operational intelligence. Josh Goryl, SkySpecs’ Chief Revenue Officer, explained their evolution at the recent Customer Forum: ‘I think where we can help our customers is getting all that data into one place.

The game-changer is integration across data types. The company is working to combine performance data with CMS data to provide valuable insights into turbine health. This approach has been informed by operators across the world, who’ve discovered that integrated platforms deliver insights that siloed data can’t.

The platform approach also addresses the reality of shrinking engineering teams managing expanding portfolios. As Goryl noted, many wind engineers are now responsible for solar and battery storage assets as well. One platform managing multiple technologies through a unified interface becomes essential for operational efficiency.

The Integration Imperative for Wind Farm Operations

The most successful operators aren’t just adopting individual technologies; they’re integrating monitoring, inspection, and repair into a seamless operational system. This integration operates at multiple levels.

At the technical level, data from various monitoring systems feeds into unified platforms that provide comprehensive asset visibility. These platforms don’t just display data; they analyze patterns, predict failures, and generate work orders.

At the organizational level, integration means breaking down barriers between departments. This cross-functional collaboration transforms O&M from a cost center into a value driver. Building your improvement roadmap For operators ready to enhance their O&M approach, the path forward involves several key steps:

Assessing the Current State of your Wind Energy Operations

Document your maintenance costs, failure rates, and downtime patterns. Identify which problems consume the most resources and which assets are most critical to your wind farm operations.

Start with targeted pilots Rather than attempting wholesale transformation, begin with focused initiatives targeting your biggest pain points. Whether it’s blade monitoring, gearbox sensors, or repair innovations, starting with your largest issue will help you see the biggest benefit.

• Invest in integration, not just technology: the most sophisticated monitoring system is worthless if its data isn’t acted upon. Ensure your organization has the processes and culture to transform data into decisions – this is the first step to profitability in your wind farm operations.

Build partnerships, not just contracts: look for technology providers and service companies willing to share knowledge, not just deliver services. The goal is building capability, not dependency.

• Measure and iterate: track the impact of each initiative on your key performance indicators. Use lessons learned to refine your approach and guide future investments.

The competitive advantage

The wind industry has reached an inflection point. With increasingly large and complex turbines, monitoring needs to adapt with it. The era of flying blind is over.

In an industry where margins continue to compress and competition intensifies, operational excellence has become a key differentiator. Those who master the integration of monitoring, inspection, and repair will thrive. Those who cling to reactive maintenance face escalating costs and declining competitiveness.

The technology exists. The business case is proven. The early adopters are already reaping the benefits. The question isn’t whether to transform your O&M approach, but how quickly you can adapt to this new reality. In the race to operational excellence, the winners will be those who act decisively to embrace the efficiency revolution reshaping wind operations.

Unless otherwise noted, images here are from We4C Rotorblade Specialist.

Wind Industry Operations: In Wind's Next Chapter, Operations take center stage

Contact us for help understanding your lightning damage, future risks, and how to get more uptime from your equipment.

Download the full article from PES Wind here

Find a practical guide to solving lightning problems and filing better insurance claims here

Wind Industry Operations: In Wind's Next Chapter, Operations take center stage

Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage

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BladeBUG Tackles Serial Blade Defects with Robotics

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BladeBUG Tackles Serial Blade Defects with Robotics

Chris Cieslak, CEO of BladeBug, joins the show to discuss how their walking robot is making ultrasonic blade inspections faster and more accessible. They cover new horizontal scanning capabilities for lay down yards, blade root inspections for bushing defects, and plans to expand into North America in 2026.

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 YouTubeLinkedin 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: Chris, welcome back to the show.

Chris Cieslak: It’s great to be back. Thank you very much for having me on again.

Allen Hall: It’s great to see you in person, and a lot has been happening at Blade Bugs since the last time I saw Blade Bug in person. Yeah, the robot. It looks a lot different and it has really new capabilities.

Chris Cieslak: So we’ve continued to develop our ultrasonic, non-destructive testing capabilities of the blade bug robot.

Um, but what we’ve now added to its capabilities is to do horizontal blade scans as well. So we’re able to do blades that are in lay down yards or blades that have come down for inspections as well as up tower. So we can do up tower, down tower inspections. We’re trying to capture. I guess the opportunity to inspect blades after transportation when they get delivered to site, to look [00:01:00] for any transport damage or anything that might have been missed in the factory inspections.

And then we can do subsequent installation inspections as well to make sure there’s no mishandling damage on those blades. So yeah, we’ve been just refining what we can do with the NDT side of things and improving its capabilities

Joel Saxum: was that need driven from like market response and people say, Hey, we need, we need.

We like the blade blood product. We like what you’re doing, but we need it here. Or do you guys just say like, Hey, this is the next, this is the next thing we can do. Why not?

Chris Cieslak: It was very much market response. We had a lot of inquiries this year from, um, OEMs, blade manufacturers across the board with issues within their blades that need to be inspected on the ground, up the tap, any which way they can.

There there was no, um, rhyme or reason, which was better, but the fact that he wanted to improve the ability of it horizontally has led the. Sort of modifications that you’ve seen and now we’re doing like down tower, right? Blade scans. Yeah. A really fast breed. So

Joel Saxum: I think the, the important thing there is too is that because of the way the robot is built [00:02:00] now, when you see NDT in a factory, it’s this robot rolls along this perfectly flat concrete floor and it does this and it does that.

But the way the robot is built, if a blade is sitting in a chair trailing edge up, or if it’s flap wise, any which way the robot can adapt to, right? And the idea is. We, we looked at it today and kind of the new cage and the new things you have around it with all the different encoders and for the heads and everything is you can collect data however is needed.

If it’s rasterized, if there’s a vector, if there’s a line, if we go down a bond line, if we need to scan a two foot wide path down the middle of the top of the spa cap, we can do all those different things and all kinds of orientations. That’s a fantastic capability.

Chris Cieslak: Yeah, absolutely. And it, that’s again for the market needs.

So we are able to scan maybe a meter wide in one sort of cord wise. Pass of that probe whilst walking in the span-wise direction. So we’re able to do that raster scan at various spacing. So if you’ve got a defect that you wanna find that maximum 20 mil, we’ll just have a 20 mil step [00:03:00] size between each scan.

If you’ve got a bigger tolerance, we can have 50 mil, a hundred mil it, it’s so tuneable and it removes any of the variability that you get from a human to human operator doing that scanning. And this is all about. Repeatable, consistent high quality data that you can then use to make real informed decisions about the state of those blades and act upon it.

So this is not about, um, an alternative to humans. It’s just a better, it’s just an evolution of how humans do it. We can just do it really quick and it’s probably, we, we say it’s like six times faster than a human, but actually we’re 10 times faster. We don’t need to do any of the mapping out of the blade, but it’s all encoded all that data.

We know where the robot is as we walk. That’s all captured. And then you end up with really. Consistent data. It doesn’t matter who’s operating a robot, the robot will have those settings preset and you just walk down the blade, get that data, and then our subject matter experts, they’re offline, you know, they are in their offices, warm, cozy offices, reviewing data from multiple sources of robots.

And it’s about, you know, improving that [00:04:00] efficiency of getting that report out to the customer and letting ’em know what’s wrong with their blades, actually,

Allen Hall: because that’s always been the drawback of, with NDT. Is that I think the engineers have always wanted to go do it. There’s been crush core transportation damage, which is sometimes hard to see.

You can maybe see a little bit of a wobble on the blade service, but you’re not sure what’s underneath. Bond line’s always an issue for engineering, but the cost to take a person, fly them out to look at a spot on a blade is really expensive, especially someone who is qualified. Yeah, so the, the difference now with play bug is you can have the technology to do the scan.

Much faster and do a lot of blades, which is what the de market demand is right now to do a lot of blades simultaneously and get the same level of data by the review, by the same expert just sitting somewhere else.

Chris Cieslak: Absolutely.

Joel Saxum: I think that the quality of data is a, it’s something to touch on here because when you send someone out to the field, it’s like if, if, if I go, if I go to the wall here and you go to the wall here and we both take a paintbrush, we paint a little bit [00:05:00] different, you’re probably gonna be better.

You’re gonna be able to reach higher spots than I can.

Allen Hall: This is true.

Joel Saxum: That’s true. It’s the same thing with like an NDT process. Now you’re taking the variability of the technician out of it as well. So the data quality collection at the source, that’s what played bug ducts.

Allen Hall: Yeah,

Joel Saxum: that’s the robotic processes.

That is making sure that if I scan this, whatever it may be, LM 48.7 and I do another one and another one and another one, I’m gonna get a consistent set of quality data and then it’s goes to analysis. We can make real decisions off.

Allen Hall: Well, I, I think in today’s world now, especially with transportation damage and warranties, that they’re trying to pick up a lot of things at two years in that they could have picked up free installation.

Yeah. Or lifting of the blades. That world is changing very rapidly. I think a lot of operators are getting smarter about this, but they haven’t thought about where do we go find the tool.

Speaker: Yeah.

Allen Hall: And, and I know Joel knows that, Hey, it, it’s Chris at Blade Bug. You need to call him and get to the technology.

But I think for a lot of [00:06:00] operators around the world, they haven’t thought about the cost They’re paying the warranty costs, they’re paying the insurance costs they’re paying because they don’t have the set of data. And it’s not tremendously expensive to go do. But now the capability is here. What is the market saying?

Is it, is it coming back to you now and saying, okay, let’s go. We gotta, we gotta mobilize. We need 10 of these blade bugs out here to go, go take a scan. Where, where, where are we at today?

Chris Cieslak: We’ve hads. Validation this year that this is needed. And it’s a case of we just need to be around for when they come back round for that because the, the issues that we’re looking for, you know, it solves the problem of these new big 80 a hundred meter plus blades that have issues, which shouldn’t.

Frankly exist like process manufacturer issues, but they are there. They need to be investigated. If you’re an asset only, you wanna know that. Do I have a blade that’s likely to fail compared to one which is, which is okay? And sort of focus on that and not essentially remove any uncertainty or worry that you have about your assets.

’cause you can see other [00:07:00] turbine blades falling. Um, so we are trying to solve that problem. But at the same time, end of warranty claims, if you’re gonna be taken over these blades and doing the maintenance yourself, you wanna know that what you are being given. It hasn’t gotten any nasties lurking inside that’s gonna bite you.

Joel Saxum: Yeah.

Chris Cieslak: Very expensively in a few years down the line. And so you wanna be able to, you know, tick a box, go, actually these are fine. Well actually these are problems. I, you need to give me some money so I can perform remedial work on these blades. And then you end of life, you know, how hard have they lived?

Can you do an assessment to go, actually you can sweat these assets for longer. So we, we kind of see ourselves being, you know, useful right now for the new blades, but actually throughout the value chain of a life of a blade. People need to start seeing that NDT ultrasonic being one of them. We are working on other forms of NDT as well, but there are ways of using it to just really remove a lot of uncertainty and potential risk for that.

You’re gonna end up paying through the, you know, through the, the roof wall because you’ve underestimated something or you’ve missed something, which you could have captured with a, with a quick inspection.

Joel Saxum: To [00:08:00] me, NDT has been floating around there, but it just hasn’t been as accessible or easy. The knowledge hasn’t been there about it, but the what it can do for an operator.

In de-risking their fleet is amazing. They just need to understand it and know it. But you guys with the robotic technology to me, are bringing NDT to the masses

Chris Cieslak: Yeah.

Joel Saxum: In a way that hasn’t been able to be done, done before

Chris Cieslak: that. And that that’s, we, we are trying to really just be able to roll it out at a way that you’re not limited to those limited experts in the composite NDT world.

So we wanna work with them, with the C-N-C-C-I-C NDTs of this world because they are the expertise in composite. So being able to interpret those, those scams. Is not a quick thing to become proficient at. So we are like, okay, let’s work with these people, but let’s give them the best quality data, consistent data that we possibly can and let’s remove those barriers of those limited people so we can roll it out to the masses.

Yeah, and we are that sort of next level of information where it isn’t just seen as like a nice to have, it’s like an essential to have, but just how [00:09:00] we see it now. It’s not NDT is no longer like, it’s the last thing that we would look at. It should be just part of the drones. It should inspection, be part of the internal crawlers regimes.

Yeah, it’s just part of it. ’cause there isn’t one type of inspection that ticks all the boxes. There isn’t silver bullet of NDT. And so it’s just making sure that you use the right system for the right inspection type. And so it’s complementary to drones, it’s complimentary to the internal drones, uh, crawlers.

It’s just the next level to give you certainty. Remove any, you know, if you see something indicated on a a on a photograph. That doesn’t tell you the true picture of what’s going on with the structure. So this is really about, okay, I’ve got an indication of something there. Let’s find out what that really is.

And then with that information you can go, right, I know a repair schedule is gonna take this long. The downtime of that turbine’s gonna be this long and you can plan it in. ’cause everyone’s already got limited budgets, which I think why NDT hasn’t taken off as it should have done because nobody’s got money for more inspections.

Right. Even though there is a money saving to be had long term, everyone is fighting [00:10:00] fires and you know, they’ve really got a limited inspection budget. Drone prices or drone inspections have come down. It’s sort, sort of rise to the bottom. But with that next value add to really add certainty to what you’re trying to inspect without, you know, you go to do a day repair and it ends up being three months or something like, well

Allen Hall: that’s the lightning,

Joel Saxum: right?

Allen Hall: Yeah. Lightning is the, the one case where every time you start to scarf. The exterior of the blade, you’re not sure how deep that’s going and how expensive it is. Yeah, and it always amazes me when we talk to a customer and they’re started like, well, you know, it’s gonna be a foot wide scarf, and now we’re into 10 meters and now we’re on the inside.

Yeah. And the outside. Why did you not do an NDT? It seems like money well spent Yeah. To do, especially if you have a, a quantity of them. And I think the quantity is a key now because in the US there’s 75,000 turbines worldwide, several hundred thousand turbines. The number of turbines is there. The number of problems is there.

It makes more financial sense today than ever because drone [00:11:00]information has come down on cost. And the internal rovers though expensive has also come down on cost. NDT has also come down where it’s now available to the masses. Yeah. But it has been such a mental barrier. That barrier has to go away. If we’re going going to keep blades in operation for 25, 30 years, I

Joel Saxum: mean, we’re seeing no

Allen Hall: way you can do it

Joel Saxum: otherwise.

We’re seeing serial defects. But the only way that you can inspect and or control them is with NDT now.

Allen Hall: Sure.

Joel Saxum: And if we would’ve been on this years ago, we wouldn’t have so many, what is our term? Blade liberations liberating

Chris Cieslak: blades.

Joel Saxum: Right, right.

Allen Hall: What about blade route? Can the robot get around the blade route and see for the bushings and the insert issues?

Chris Cieslak: Yeah, so the robot can, we can walk circumferentially around that blade route and we can look for issues which are affecting thousands of blades. Especially in North America. Yeah.

Allen Hall: Oh yeah.

Chris Cieslak: So that is an area that is. You know, we are lucky that we’ve got, um, a warehouse full of blade samples or route down to tip, and we were able to sort of calibrate, verify, prove everything in our facility to [00:12:00] then take out to the field because that is just, you know, NDT of bushings is great, whether it’s ultrasonic or whether we’re using like CMS, uh, type systems as well.

But we can really just say, okay, this is the area where the problem is. This needs to be resolved. And then, you know, we go to some of the companies that can resolve those issues with it. And this is really about played by being part of a group of technologies working together to give overall solutions

Allen Hall: because the robot’s not that big.

It could be taken up tower relatively easily, put on the root of the blade, told to walk around it. You gotta scan now, you know. It’s a lot easier than trying to put a technician on ropes out there for sure.

Chris Cieslak: Yeah.

Allen Hall: And the speed up it.

Joel Saxum: So let’s talk about execution then for a second. When that goes to the field from you, someone says, Chris needs some help, what does it look like?

How does it work?

Chris Cieslak: Once we get a call out, um, we’ll do a site assessment. We’ve got all our rams, everything in place. You know, we’ve been on turbines. We know the process of getting out there. We’re all GWO qualified and go to site and do their work. Um, for us, we can [00:13:00] turn up on site, unload the van, the robot is on a blade in less than an hour.

Ready to inspect? Yep. Typically half an hour. You know, if we’ve been on that same turbine a number of times, it’s somewhere just like clockwork. You know, muscle memory comes in, you’ve got all those processes down, um, and then it’s just scanning. Our robot operator just presses a button and we just watch it perform scans.

And as I said, you know, we are not necessarily the NDT experts. We obviously are very mindful of NDT and know what scans look like. But if there’s any issues, we have a styling, we dial in remote to our supplement expert, they can actually remotely take control, change the settings, parameters.

Allen Hall: Wow.

Chris Cieslak: And so they’re virtually present and that’s one of the beauties, you know, you don’t need to have people on site.

You can have our general, um, robot techs to do the work, but you still have that comfort of knowing that the data is being overlooked if need be by those experts.

Joel Saxum: The next level, um, commercial evolution would be being able to lease the kit to someone and or have ISPs do it for [00:14:00] you guys kinda globally, or what is the thought

Chris Cieslak: there?

Absolutely. So. Yeah, so we to, to really roll this out, we just wanna have people operate in the robots as if it’s like a drone. So drone inspection companies are a classic company that we see perfectly aligned with. You’ve got the sky specs of this world, you know, you’ve got drone operator, they do a scan, they can find something, put the robot up there and get that next level of information always straight away and feed that into their systems to give that insight into that customer.

Um, you know, be it an OEM who’s got a small service team, they can all be trained up. You’ve got general turbine technicians. They’ve all got G We working at height. That’s all you need to operate the bay by road, but you don’t need to have the RAA level qualified people, which are in short supply anyway.

Let them do the jobs that we are not gonna solve. They can do the big repairs we are taking away, you know, another problem for them, but giving them insights that make their job easier and more successful by removing any of those surprises when they’re gonna do that work.

Allen Hall: So what’s the plans for 2026 then?

Chris Cieslak: 2026 for us is to pick up where 2025 should have ended. [00:15:00] So we were, we were meant to be in the States. Yeah. On some projects that got postponed until 26. So it’s really, for us North America is, um, what we’re really, as you said, there’s seven, 5,000 turbines there, but there’s also a lot of, um, turbines with known issues that we can help determine which blades are affected.

And that involves blades on the ground, that involves blades, uh, that are flying. So. For us, we wanna get out to the states as soon as possible, so we’re working with some of the OEMs and, and essentially some of the asset owners.

Allen Hall: Chris, it’s so great to meet you in person and talk about the latest that’s happening.

Thank you. With Blade Bug, if people need to get ahold of you or Blade Bug, how do they do that?

Chris Cieslak: I, I would say LinkedIn is probably the best place to find myself and also Blade Bug and contact us, um, through that.

Allen Hall: Alright, great. Thanks Chris for joining us and we will see you at the next. So hopefully in America, come to America sometime.

We’d love to see you there.

Chris Cieslak: Thank you very [00:16:00] much.

BladeBUG Tackles Serial Blade Defects with Robotics

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Understanding the U.S. Constitution

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Hillsdale College is a rightwing Christian extremist organization that ostensibly honors the United States Constitution.

Here’s their quiz, which should be called the “Constitutional Trivia Quiz.”, whose purpose is obviously to convince Americans of their ignorance.

When I teach, I’m going for understanding of the topic, not the memorization of useless information.

Understanding the U.S. Constitution

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