Weather Guard Lightning Tech
Energex Acquisition, LM Wind Power Builds Enercon Blades
We discuss the recent acquisition of Energex Renewable Energy by CDPQ for $3.6 billion, highlighting its implications on the wind industry. We also delve into LM Wind Power producing blades for ENERCON from its factory in Turkey and feature the Buffalo Mountain Wind Farm, a unique project on a reclaimed coal mine in Tennessee.
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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!
You are listening to the Uptime Wind Energy Podcast brought to you by build turbines.com. Learn, train, and be a part of the Clean Energy Revolution. Visit build turbines.com today. Now here’s your hosts, Allen Hall, Joel Saxum, Phil Totaro, and Rosemary Barnes.
Allen Hall: Big news, Energex Renewable Energy has announced that it will be acquired by CDPQ.
A major community and pension fund manager for about $13 and 75 cents per share. I’ve seen a couple different numbers about that. This transaction represents a total enterprise value of approximately 3.6 billion US dollars, and marks a really a substantial consolidation in the wind industry. The deal offers about a 40% premium on interjects closing share.
Of a couple months ago. So that’s a pretty good premium that CDPQ put on interjects value. And now Phil, this is part of a larger play of a lot of consolidation. This one in particular, interject is going to become a private company after this acquisition. Why?
Phil Totaro: It, that’s an interesting question because normally when a company gets taken private by a large institutional investor, it’s to restructure.
I am not sure that. Energex needs that much restructuring per se. It’s not like they’ve got a huge team to begin with. But a reasonably competent team in terms of the pedigree of their developments, obviously in Canada and throughout Europe as well. And they’ve been trying to venture off and dip their toe in other markets as well.
The reality of this is that it, it’s a fantastic thing for CDPQ to strengthen their position and it comes at a point in time when a lot of these Canadian pension funds are looking at the profitability and the returns that they’re seeing on their investments globally, including the US right now with all the trade tensions and everything we’ve got.
And I think you’re gonna see more of these Canadian. Pension funds and investors pulling back and doing things that are ignoring the US at this point. Looking at deals in Canada, looking at deals in Europe, looking at deals in Southeast Asia and South America for that matter.
Joel Saxum: I think it makes sense for me like CDPQ keeping their Canadian money mostly in Canada. However, I know Energex has a hand small handful of wind farms in the United States as well. Did you see a reality where just because of geopolitical reasons, they might just. Sell those couple of wind farms off.
Phil Totaro: Let’s put it this way, Brookfield’s not going anywhere and they’re always on the hunt for, good assets.
But there’s other people that could want to gobble up wind assets right now, especially if, the assets that Enerex owns in the US they’re not quite ready for repowering yet. But maybe that’s part of the play.
Joel Saxum: Moving forward. Yeah, I know, like you said, you mentioned Brookfield.
Brookfield, same thing. We’re talking about market consolidation. They just bought National Grid renewables not too long ago, and I know National Grid renewables in the States. A couple, A handful of wind farms and some solar assets, some other things. So yes, continuing to see that trend.
Allen Hall: I still wonder though if taking them private is a better long-term play.
Because of the turbulence that’s gonna happen over the next couple of years. It gets rid of all the shareholder complaints and the back and forth and where to save money and whatnot. If you’re really trying to look for a longer play, doesn’t taking renewable assets, especially large scale renewable assets off the public markets, the better long-term play.
I just think that. There’s so much turbulence in renewable energy, and it’s getting bashed so much that the value was still there, but in the public eye, it’s like it doesn’t have as much value. But when you’re producing power and you’re delivering it and getting paid, you’re still making money.
Phil Totaro: Maybe to answer that question. I think again, the reason that you would take something private is if you wanna avoid the scrutiny in general. And the reason to wanna avoid the scrutiny at this point is partly what you just described, but I think mainly if you’re looking to own and operate for a longer term, this is something, and look, CDPQ is putting money into something that they’re not making a short-term play themselves either. This isn’t just, Hey, let’s buy Inex to flip it in a year and a half or something. They’re, if they’re. Going in like they did with a minority stake that they’ve got in energy or any other investments that they’ve got and partnerships they’ve got around the world on individual projects or with development and owner operator companies then, they’re very deliberate about what they’ve done.
So again, taking it private. To me feels like they want to, just go about their business for the time being.
Allen Hall: Would the Canadian US tariff exchanges influence that decision
Phil Totaro: A little bit. I. Not necessarily a take private deal specifically, but you’ve got a scenario where, again, there, the Canadian pension funds and institutional investors, which is also gonna include, the likes of CDPQ and Brookfield.
They are going to make it a point to de-emphasize investments in the US for the time being, because there’s, it’s, and it’s really not even, ’cause look, we talked about this on the show before. If we end up in a recession and interest rates end up coming down, that’s actually really good for investors because they wanna plow money in when the cost of money’s cheap, if interest rates are low.
But the reality of it is we’re not quite there yet. We’re not, all the way into a recession yet there’s, everybody’s still on the fence. The what they’re, what everyone’s trying to avoid right now is the chaos that’s ensuing from the uncertainty around. The tariffs that are either in place, not in place, now they’re in place again.
We had Ontario trying to impose tariffs on the energy exports. Now they’re not, because there was a conversation with the commerce department. So I, who knows what’s gonna happen. This is the problem. Nobody knows what the hell’s gonna happen tomorrow. So how the hell can you plan financially?
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Visit EOLOGIX-PING.com and take control of your turbine’s health today. LM Windpower has announced an extension of its partnership with Evolv. Company’s Intercon leading wind turbine provider, obviously. Through a new contract that’ll supply LM 78.3 meter blades for intercom’s, E one 60, EP five, E two wind turbines.
This, these blades are gonna be manufactured over in Turkey at the end of this year and it. It seems like LM is moving away from manufacturing GE equipment to picking up some work for other manufacturers. I, we’ve been noticing this trend for several months now. It does seem like this alliance falls into that bucket of maybe LM is moving on a little bit, but Turkey, the thing about this is LM getting work in Turkey because it did seem like a lot of.
Companies were starting to pull out a Turkey. Intercon is starting to fill the void. Isn’t that what it looks like, Phil?
Phil Totaro: Yes. Although this is slightly confusing. ’cause if you remember last year they were talking about laying everybody off in Turkey at LM and shutting the whole factory because I thought Intercon was working with TPI, who also has a facility there on the manufacturing of blades.
So did something happen? And if so, what? I don’t think we know. But also this, this deal, while it’s obviously not necessarily bad news for lm, keep in mind there’s only five or so gigawatts of order book for these intercon turbines. That’s specific model of turbine. So it’s not like this is game changing for lm and it’s not oh, this is gonna save the company, it’ll keep a factory in Turkey operational for.
18 months while they produce these things. And then after that, I don’t know what happens. ’cause intercom’s not been like the strongest in terms of their global sales lately. So we’ll see.
Joel Saxum: Yeah. So Rosemary, you worked at lm as part of some special projects. Of course you had one that was your general remit, but when things came through the door from other manufacturers of turbines, intercon being one of ’em, Intercon builds the turbine itself. They don’t build their own blades. How was that handled within lm? Do you, did you have any experience with that?
Rosemary Barnes: So when I started at lm, there was nothing but other companies blades, right? LM Wind Power didn’t make turbines and so the blades they made were exclusively for other manufacturers to put another manufacturers turbines.
And then a couple of years. Into my time at lm, I think must have been about 2018 or something. They got bought by ge who had been one of their main customers, one of the biggest customers. And wanted to, reduce some of the supply chain uncertainty by bringing that in-house.
And at the time there was lots and lots of reassurances of, we wouldn’t have paid so much for the company if we didn’t want you to still be making blades for other customers, and nothing’s gonna change there. There was a lot of effort put into they call them Chinese walls, right? Where like just because you’re working on one manufacturer’s technology, you just can’t go and work on their competitors and tell them all the, all their secrets and stuff like that.
I’d say that they did that as well as they probably could have not perfect. I’m sure. But yeah, as time’s gone on, I think that a lot of the other manufacturers got a little bit didn’t feel super duper comfortable even, with those things in place. There is of course still the worry that you’re just telling your competitor all of yeah, everything they need to know to just copy what you’re doing.
I think people have got less keen on it. Yeah, in a sense, like when I left LM it was only a couple of years into the merge and it really, things didn’t feel that different in terms of working for other manufacturers, but I’m sure that five years later it does. And so this is maybe more of a.
More of a big deal now, but yeah, to me it’s just the way that every project was. It didn’t make any difference if a blade was to be made for GE versus any of the other manufacturers.
Joel Saxum: I know Allen, with some of our work we’ve done with lightning protection in India, we’ve seen Intercon turbines with.
LM Blades, and I think we’ve seen Envision turbines with LM blades in India as well, haven’t we?
Allen Hall: Yes, we have.
Joel Saxum: Definitely.
Rosemary Barnes: I think LM made blades for maybe literally every single manufacturer. There were a few that they didn’t make many for. I know Vestas was one that they were continuously chasing and had never.
At the time I was working there, they had never really done a lot for vest and were always wanting to, but for the most part, I’m pretty sure that they had at least dabbled with every single OEM and I myself had some meetings at Anacon for yeah, for a deicing a blade that had deicing systems and it was very it was culturally very different to other manufacturers that I had worked with.
I worked a lot with ge and. A bit with Siemens Gomesa and just, I just did some introductory meetings at Anacon and it was exactly like you would expect the German engineering stereotype to, exactly like that would tell you. They really wanted things optimized. I’m much more of a, you make things.
As good as they need to be and not better because when you make them better, you make them more expensive, you make them take longer, you can often add extra points of failure that you know didn’t need to be there if the feature is a bit unnecessary. Yeah. But when you talk to. Maintenance personnel service teams, they love servicing anacon turbines.
I’ve heard it described over and over again as the Mercedes of wind turbines. They say, I’ve never climbed one, but they say that when you get up there, it is like the interior of a, I dunno, luxury yacht or something.
Allen Hall: As wind energy professionals staying informed is crucial and let’s face it difficult.
That’s why the Uptime podcast recommends PES Wind Magazine. PES Wind offers a diverse range of in-depth articles and expert insights that dive into the most pressing issues facing our energy future. Whether you’re an industry veteran or new to wind, PES Wind has the high quality content you need. Don’t miss out.
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Joel Saxum: Isn’t it true with Intercon as well that they’d like, they won’t sell a turbine unless they get the maintenance contract
Phil Totaro: in Germany? Yes. I think they’ve had to relent in other countries because again, financiers may not allow that. To, like it’s just, oh, this is way too expensive.
’cause like a lot of OEMs, no matter how much an intercon turbine costs, when they’re also selling the maintenance package, they’re trying to make whatever they feel like they lost on the upfront CapEx and turbine costs up with the long-term service contract. They.
It just depends on which market. Definitely in Germany, they, I don’t think they’ll sell a turbine unless it’s their maintenance because they are so well-oiled. And you could probably argue almost all of Western Europe they’re so well-oiled in terms of, I, I heard a story once when I was at Clipper, this would’ve been around 2009, where there was a.
Intercon turbine in Germany that had a nelle fire and they literally had a brand new Nelle in 24 hours. They had swapped it, they had been able to swap out a newness cell and had the turbine back up and running within 24 hours of that fire, which is just astonishing. You’re paying for it like Rosie’s talking about, you’re paying for it.
Rosemary Barnes: That’s the kind of benefit that you would expect to see when you have OEM service agreement, right? That they have the ability to keep an inventory of spare parts and, nearby and they can just swap stuff out and everything’s very fast, but. We don’t see in Australia where those kind of agreements are very common.
We don’t see, we don’t see that kind of preferential treatment, that’s for sure. And then the second thing is that it may be technically the OEMs aren’t requiring that if you buy their turbines, you have to buy their service agreements. I. It’s almost like a, I don’t know, like a strong man kind of sales tactics.
Like sure you can, self self support this, self service this, but good luck getting any spare parts for it. Good luck getting any help. If you’ve got a, a warranty claim and they like pressure so much that you have no choice, which to me, like I would rather. That they were just honest, that they’re like, we can’t make a profit on the turbine without the service.
So you have to buy the service like that. I would rather know and have it, be honest about it than pretend like you’ve got a choice, but you’re just gonna be, like bullied and yeah, this thuggery to, to force you into using, or they’ll go outta their way to make your life hard.
Phil Totaro: And this, frankly, this is also what’s been talked about lately is that with people not being able to get access to spares for some, older.
Turbines and older models of blade. There are companies out there that are having the conversation. Do we just reverse engineer, one of these, one of these blades? Do we just buy one and scan it and figure out the arrow profiles and then. We already know how to manufacture a blade of that style anyway, so we’re just gonna do our own version.
And there are OEMs that are discussing that literally right now because they wanna be able to sell spare parts. Basically, and that’s probably extends beyond blades, but they wanna be able to sell spare parts to a market that is thirsty for spare parts. And it’s certainly happening, it’s conversations that are happening in the us but I could imagine it’s something that they would talk about in Australia too, because access to spares down there is also, quite finite and or time consuming to get your hands on.
Rosemary Barnes: One of the things, even, yeah back in my early LM days, that was one of the things that I learned early on. ’cause I was shocked at the secrecy and everyone rolled their eyes and said, it’s so dumb anyway, because the big customers, like if they buy hundreds of turbines worth of blades, then they buy an extra, one extra blade and slice it up into, I don’t know a hundred millimeter slices and then they can easily reverse engineer.
Maybe they don’t know. Exact materials, although I’m sure that it wouldn’t be too hard to do that either. Like you’re not gonna get a hundred percent of the way there. But I do think you could get like 95% of the way there and, do your own engineering on top to, do the analysis to, to make sure it’s okay.
So that, that’s why I think that the excessive secret is. Secrecy is silly because you send the you sell the product, you’re not in control of it anymore. Once it’s, left you, then why is it impossible to get from the OEM? Just like a simple line drawing that tells you where within the blade the lightning cable goes for instance, there’s just no reason for them to be um, like just to have their white knuckled grip on the, those drawings that they can’t even share.
Basic information like that, that you need to use their product properly when all you need to do is just yeah, you don’t even need to buy a spam, just wait till you’ve you’ve got a failure and okay, we’re not scrapping this blade, we’re slicing it. And then you’ll get all the information you need.
And, but with a harm drip relationship between customer and supplier, it doesn’t I don’t feel the need to make such an adversarial relationship over that.
Joel Saxum: The Wind Farm of the week this week is inspired by our A-C-P-O-M-S trip last week to Nashville. And it is one of the only wind farms within the state of Tennessee.
It’s called the Buffalo Mountain Wind Farm. It’s an old one. It’s been around for a long time. Started in October of 2000, so it’s in Anderson County, Tennessee, and it was the home of the first commercial wind generation facility in the southeastern United States. It’s owned by the Tennessee Valley Authority TVA, which is also the nation’s largest public power company, which I did not know.
They started by building three turbines up on top of a, former strip coal mine. So these were 660 kilowatt turbines. And they powered about a four, 400 homes. But then they expanded the wind farm in 2004 after it was successful to have 15 turbines. As of April, 2003, they’ve had 15 turbines and they’re producing about 9,500 megawatt hours of electricity per year.
The cool thing about this, like I was saying though, is this, is, this wind farm is located at the top. Of an abandoned or backfilled reclaimed coal mine. So the Coal Creek Mining Company was a part of this thing and it was a part of TVA’s Green Switch program. So this is using a, an formerly operated strip mine in Tennessee to produce renewable green energy with a 29 megawatt wind farm.
And energy works with TVA to run it. So the Buffalo Mountain Wind Farm. In Tennessee, you are the Wind Farm of the week.
Allen Hall: That’s gonna 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 or weekly substack newsletter and subscribe to engineering with Rosie because she’s going to hit 100,000 subscribers sometime over the next week or two.
We’ll see you here next week on the Uptime Wind Energy Podcast.
https://weatherguardwind.com/energex-lm-windpower-enercon/
As shown here, there are (formerly credible) people who are telling us that Trump is restoring Americans’ trust in government.
Do they truly believe this?
One of the casualties of the post-truth era is that the statements of our “leaders” no longer are required to have any basis in fact. What Jim Jordan says here is a fine example.
When he says “better” here, is he referring to runaway inflation? Trump’s purposeless and illegal war with no end in sight? His blatant corruption and criminality? His having, quite successfully, divided the American people into groups that hate each other? The enrichment of billionaires at the expense of the working class? The carefully engineered collapse of the environment so as to favor his donors in fossil fuels? The demise of the U.S. educational system?
Please be clear.
Weather Guard Lightning Tech
CNC Onsite Cuts Repair Costs With Uptower Machining
Søren Kellenberger, CEO of CNC Onsite, joins to discuss uptower yaw gear repairs, flat tower flanges, and replacing 1,000 blade root bushings across 26 turbines.
Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTube, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!
Allen Hall 2025: Soren, welcome back to the podcast.
Søren Kellenberger: Thank you, Allen, and, uh, nice doing it, uh, face-to-face- Yes, it’s great … and not as a team, uh, call. Right. That’s
Allen Hall 2025: true. Yeah. You’ve been doing a good bit of traveling, and you’re the new head of CNC Onsite.
Søren Kellenberger: I am, yes.
Allen Hall 2025: So congratulations on that.
Søren Kellenberger: Thank you very much.
Allen Hall 2025: And all the exciting new things that CNC Onsite [00:01:00] is doing, plus all the things you have developed and are now out in the field implementing, the, the list goes on and on and on.
I’m alwa- every time I talk to you, “Oh, we got a new-” Yeah … “machine to do something uptower.” So it’s all uptower, which is the, the beauty of CNC Onsite. You’re thinking about the operator and the cost to pull the blades off and do lifting the cell off and all those things. If we can do it uptower, we can save 30, 40, 50% of the cost of a repair.
Søren Kellenberger: Yeah.
Allen Hall 2025: That’s where CNC Onsite is just really killing it. You guys are doing great. Thank
Søren Kellenberger: you. Of course, we like what we do, but, uh, thank you.
Allen Hall 2025: Yeah. Yeah. Yeah, yeah. No, it’s good, it’s good. And, and so w- let’s talk about the things that I know about, and we’ll start there, and then we’ll go to all the new things you’re doing.
So the one that I see a lot of operators asking about is yaw tooth. Yeah.
Søren Kellenberger: Uh,
Allen Hall 2025: deformations, broken teeth on the yaw gear. That’s a big problem. And when I talk to [00:02:00] technicians, and I have them texting me about this, like, “Oh, well, I just weld on the gear back on, weld the tooth back on.” That’s a short-term solution.
That’s not gonna be long-term. The long-term solution is the CNC Onsite. Can you explain what you do to permanently fix these yaw gear problems?
Søren Kellenberger: Yeah. So what we do is actually we start by getting information about the, uh, original yaw ring, so the dimension of the teeth, and we get some load data. And, uh, then we start designing a replacement segment.
Uh, so what we ac- the process is actually that we bring a CNC controlled machine uptower, mount it on the yaw ring, and then we mill away that worn area, uh, creating a small pocket. And then those, uh, segments that we have designed, they are prefabricated. We bring them up and mount them in, in that, uh, pocket and bring the- The yaw ring back to where it’s, you can say, original design, uh, [00:03:00] that way.
Yeah
Allen Hall 2025: It’s better than the original design, ’cause you’re actually putting in better teeth than the, the manufacturer did originally.
Søren Kellenberger: True. Yeah, yeah.
Allen Hall 2025: So that happens, so you’re, you’re machining out those old teeth, broken teeth, putting the new set of teeth in th- and that all bolts in, and that’s it. That’s it.
But the, the difficulty is getting the machinery uptower to do that. That’s where a lot of your, your technology comes from, is getting this very accurate, uh, well-defined machine uptower and doing very controlled grinding and milling. Yes. So can you explain what that system looks like? If I’m gonna grind off those yaw, broken yaw teeth, how big is that kit?
Søren Kellenberger: It… Obviously, it depends a little bit on the turbine size. Sure, okay. Yeah. So, uh, it, so the, the newer five, six, uh, 10 megawatt turbines have larger teeth, so yeah, there you need a, a larger machine.
Allen Hall 2025: Okay.
Søren Kellenberger: But let’s say for, uh, Vestas three megawatt, the, the [00:04:00] complete machine weighs about 250 kilos. That’s it? So yeah.
So it, it comes up in smaller components. We just use, uh, the, the internal crane in, in the nacelle, and, uh, then we can lift the components to the yaw ring, assemble the machine, and then we are basically good to go. So it take, takes less than a day to get everything up and, uh, get set and be ready to, to machine.
Allen Hall 2025: So if you wanna fix a yaw gear problem, how long does it take from start to finish to get that done?
Søren Kellenberger: It typically, it takes one day to get everything up and get ready, and then per six teeth, which is a typical segment, it takes about a day to machine that. Okay. So, uh, let’s say you have, uh, somewhere between 10 and 15 teeth, it’s, uh, two to three segments.
So we do that in a week. Um-
Allen Hall 2025: Wow … and- ‘Cause the alternative is call a crane, have them lifting the cell off.
Søren Kellenberger: Yeah.
Allen Hall 2025: Take the yaw gear off, put a yaw gear on, if you can find a yaw gear. Yes. Put the nacelle back on. [00:05:00] Well, and I guess obviously the rotors are coming down too, so- Yeah. You’re talking about- Yes
hundreds of thousands of dollars in downtime. Yeah. It’s a big ordeal. The CNC Onsite method is so much easier.
Søren Kellenberger: We will just put our equipment in the back of our truck- … and then, uh, we’ll, we are ready to mobilize in a few days. So yeah, we can significantly, uh, bring down the downtime and, and as you said, the crane cost is of course extremely high.
And then you can add all the project management. You know, con- do I actually have my access roads, uh, still available? Right. Is the crane pad intact? And all of that stuff you need to organize. You can just forget about that and, uh- And
Allen Hall 2025: get it done …
Søren Kellenberger: get it done. Yeah.
Allen Hall 2025: Yeah. There’s, there’s a lot of owners, we, everybody knows who the machines are that have the, the, the yaw tooth problem.
Søren Kellenberger: Yeah.
Allen Hall 2025: So if you’re one of those owner operators, you better get ahold of CNC Onsite. Now, flanges on tower sections. It’s become a, a really critical issue. You hear a lot of, of [00:06:00] operators, OEMs talking about, “I’m putting together these tower sections and those flanges don’t really meet up quite right.”
Søren Kellenberger: Yep.
Allen Hall 2025: “I’m creating uneven torque patterns, bolt pat- my bolt tightening is not quite right.”
Søren Kellenberger: Yeah.
Allen Hall 2025: And it never really seats right, so you have this mechanical, built-in mechanical problem. CNC Onsite is now fixing that so those flanges are actually really flat. Really flat, yes. ‘Cause that’s what you need.
Søren Kellenberger: Yeah.
Allen Hall 2025: Yeah. They’re highly loaded.
Søren Kellenberger: If, if you want, uh… If you want your joints to be, uh, basically maintenance free, uh, we can, uh, achieve that with machining the flanges. And then, of course, you need to be in control with your bolt tightening process. Sure. But if you do those two things, you can have maintenance free bolted connections, and there’s so much money to be saved in the operations.
Um, and of course, when you have these bolts that end up fatiguing, some of them don’t get caught in time and you end up ha- having a catastrophic failure on the turbine. Uh- We’ve [00:07:00] seen that … because you have that zipper effect. Once a bolt starts breaking, the neighboring ones take that extra load and it accelerates really quickly.
Uh, yeah. Sure does.
Allen Hall 2025: Yeah. It’s a very serious situation, but it starts with this very simple solution which is just make the flange flat.
Søren Kellenberger: Yeah. But I think it’s some… a part of the issue is that those buying the towers aren’t necessarily responsible for the operational cost of maintaining that bolted connection.
So they might save a little bit of money when they buy the tower sections with rougher tolerances, but you will spend the money 10 times in the operations. Uh, and, and that’s, I think that’s where some of the operations, uh, re- the, the, those responsible for operational costs should, uh, get a little bit more CapEx spend, uh- Oh, sure.
Yeah. And, and then, uh, actually save a lot of money and, and reduce risk. Uh, it’s a huge, huge risk
Allen Hall 2025: It’s, it’s one of those lessons learned. You [00:08:00] don’t know that they should be flat. You shouldn’t know… You don’t know your flanges should be flat until you experience the problems, and then you want all your flanges flat from here on out.
Søren Kellenberger: Yeah.
Allen Hall 2025: But there’s only one way to do that really, and that’s to call CNC Onsite to come in and to make them flat.
Søren Kellenberger: Yeah.
Allen Hall 2025: Because it’s a difficult thing to do. You really need to have the machining prowess and the tight tolerances that CNC Onsite’s gonna deliver in a tool that can actually be adapted to that tower ring and make those surfaces flat.
It’s complicated. Exactly.
Søren Kellenberger: It is. Uh, but that is what we do every day, so, uh- Yes, I’ve noticed … yeah, so
Allen Hall 2025: so- You take on those challenges
Søren Kellenberger: So we are optimizing our machines to be not only fit for one-offs, but actually to go into a manufacturing, uh, process. So we have op- optimized our machines a lot with, uh, automatic alignment and, uh, stuff like that to, to really make that process, uh, easier.
Because it has been considered that when you had to machine a flange, you weren’t in [00:09:00] control with your production, uh, processes. But I think that is, um, a bit of a misinterpretation. It’s, it’s a little bit like saying when I have a casted component, I cannot get a bearing fit, uh, in my cast process. That’s not because your cast process is wrong, there’s just some limitations to what you can do.
Sure. And it’s basically the same here. Yes. And, and if you apply that con- uh, planned machining, you can gain some real benefits, uh, later on and the cost will, of course, drop dra- dramatically if you plan it, rather than call for one, uh, every time you have one that is out of tolerances and, and you can even narrow those tolerances down and get the benefits from maintenance-free bowler connections.
Allen Hall 2025: Right.
Søren Kellenberger: Uh-
Allen Hall 2025: Right, ’cause you’re gonna pay for it for the next 20, 30 years. Yeah. Yeah. That’s absolutely right. Now, you’re getting involved in some of the safety aspects of operating a turbine. Uh, some of the pins and the lockouts on the low-speed gearboxes get a little worn over time, so the hole [00:10:00] you put the pin in gets worn.
There’s a lot of loads on that and- Yeah … it starts to oblong out and eventually, if you’re trying to work on that gearbox, you’re trying to keep that and your technicians safe, which is what you’re doing- Yeah … that lockout pin doesn’t quite fit in the hole and it creates a little bit of a safety risk.
Yeah. So now CNC on-site’s coming in and saying, “Hey, wait a minute. We can realign that, clean that hole up, make that safe again.”
Søren Kellenberger: Yes.
Allen Hall 2025: Explain what that looks like and what that process is to do that.
Søren Kellenberger: Yeah. So again, it’s the same thought like with the, with the O-ring, uh, that instead of bringing a component down and trying to fix it, we have designed some machinery we can bring uptower and then make that repair.
So basically what we do is that, that we mill that hole a little bit larger and then we bring a bushing, uh, that we, uh, freeze into that hole- Okay … and to recreate that tight fit again with a, with a locking pin. Uh, so it’s, it’s not that [00:11:00] complicated, but you still need to know, of course, what you are doing.
So finding the center of the original hole is one of the critical things because you want the center of the new ring to be in that same position- Sure … to make sure it fits with the pin
Allen Hall 2025: right. So- Right. You can’t just take a drill up there and try to clean out that hole. No, no. That is not the way to do that
That,
Søren Kellenberger: that
Allen Hall 2025: won’t work. No, no . I’m sure it’s been tried, but- Yeah … no, you wanna have accurate mach- actual, uh, tight tolerance machinery up there to, to align that hole, drill it properly, put that insert back into that spot- Yeah … which is gonna be a hardened insert so it’ll last longer, right?
Søren Kellenberger: Yeah, yeah.
Allen Hall 2025: So once you do that, y- it’s a permanent fix to a otherwise nagging problem.
That’s wonderful.
Søren Kellenberger: Yeah.
Allen Hall 2025: So, th- again, that kit just goes right uptower, right up the, the lift, right up the cl- crane- Exactly … and bang, you’re done. Yeah. Okay.
Søren Kellenberger: So all our machines are designed to be able to be lifted with the internal crane-
Allen Hall 2025: Yeah …
Søren Kellenberger: of that specific nacelle.
Allen Hall 2025: Okay.
Søren Kellenberger: So obviously as the cells go bigger, they have more load cap- uh- Me too
load capacity. Yeah. So for the smaller [00:12:00] turbines, the machines come in, in a bit smaller parts- Okay … so that we are sure we stay within that 250 or 500 kilogram or even whatever the limit is of, of that- Yeah, yeah, yeah … crane. And then we can, uh, reassemble everything uptower and still do tolerances within a few hundredths of a millimeter.
And, and I think that is, that is really the core of, of what we do that, that we can achieve those workshop tolerances on site, um-
Allen Hall 2025: It’s crazy when I tell people that. I say, “Well, you know, CNC on-site, they can’t… I mean, those, those tolerances can’t be that tight.” And I say, “No, no, no, no. They’re talking about, you know, fractions of a millimeter,” which in, in American terms means fractions of a mil.
Yeah. That’s 1/1000th of an inch. That’s the tolerance you’re doing.
Søren Kellenberger: Yeah.
Allen Hall 2025: Uh, and that means quality at the end of the day. If you can machine things that tight, that means what you’re getting is gonna be right for that job. Yeah. It’s gonna fix that, fix that problem permanently, which is the goal. Yes. Don’t recreate the problem.
Just fix it once and be done. Now, blade root [00:13:00] inserts, huge issue. CNC on-site has been developing tooling to drill out those existing inserts and, and put in new inserts, and you’re having success with that.
Søren Kellenberger: Yeah.
Allen Hall 2025: That’s a… it seems like a complicated process, but you have owned that quite well. Talk about what that machinery looks like today, how you’re doing that process, and what have you learned from doing some, uh, field work.
Søren Kellenberger: It’s, uh… we actually, we’ve, we’ve developed two different machines now. Okay. So we, we have, we have one that is, uh, fully CNC controlled, uh, when you need to do a lot of bushings. Yeah. Um, that one takes a bit more, uh, time to set up, but, but, uh, each drilling process is, is really fast. Uh, and then we have developed a semi-automatic machine as well, uh, which is a little bit easier to mount, mounts directly on the blade.
And it’s, uh, really perfect when you only have smaller areas of the, the blade root where you don’t need to replace all bushings- But maybe typically it’s, it’s in the high load [00:14:00] area, which is 15 to 20 bushings maybe. Right. Something like that, right? Yes.
Allen Hall 2025: Yeah.
Søren Kellenberger: So, so there we can just mount it directly on the blade and, and then drill from, uh, from there.
Um, and it works really well. We completed, uh, the first large scale, uh, commercial, uh, project, uh, together with our good friends from, uh, We4C. Uh- Right.
Allen Hall 2025: Yes.
Søren Kellenberger: And, uh, and now we are producing, uh, two more drilling machines- Oh … uh, for, for new upcoming, uh, projects also together with, uh, the guys from, from We4C.
Allen Hall 2025: Wow.
Søren Kellenberger: So now it’s, it’s starting to, uh, to pick up. Um, it’s been a relatively long process, and I guess no one really wants to be the first mover on, uh, on new technology, right? Right. So we’ve had a lot of questions. Oh, that… And that looks interesting, but how many, uh, turbines, uh, or how many blades have you repaired?
And it’s been up until now, well, it’s only tested in the lab. Uh, but now we have the first, uh, large scale commercial, uh, project with, uh, 26, uh, turbines, [00:15:00] uh, repaired and, uh, and 1,000 bushings, uh, that were replaced, uh, across those, uh, 26 turbines. So-
Allen Hall 2025: Wow …
Søren Kellenberger: so I guess that is now large scale. Uh-
Allen Hall 2025: That’s large scale.
Yeah. Yeah. I would consider 1,000 a large scale test. Yeah. Yeah. Yes. And that brings all those turbines back to life.
Søren Kellenberger: Absolutely. They are up running, uh, full power again, so, uh, that is, uh-
Allen Hall 2025: That’s huge …
Søren Kellenberger: really nice.
Allen Hall 2025: For the operator, I’m sure they love that.
Søren Kellenberger: Yeah. And, and of course, uh, there’s, there’s been a lot of discussions about blades and, uh, bla- the, the waste, uh, issue you have on, on worn- Oh
out blades. Sure. So by being able to fix them instead of replacing them, not only is the, the cost for fixing a blade a lot lower than buying new ones, uh, but, but also from a, an environmental perspective. The not having to scrap them and create that waste is, uh, is also a nice, uh,
Allen Hall 2025: thing. Yeah, it’s one of the things that pops up more recently about replacing blades, and I think the [00:16:00] industry and the operators are pushing back on that.
Uh, because a lot of times the OEM wants to replace a blade, it’s just easier for them to do.
Søren Kellenberger: Yeah.
Allen Hall 2025: But the reality is, is that yeah, you’re creating this additional problem. What are you gonna do with the disposal of this blade? Do we really need to do that? Is it so far gone that I can’t recover it? I think a lot of times, especially with fiberglass blades- Yeah
you can bring them back to life.
Søren Kellenberger: Yeah.
Allen Hall 2025: Just with a little bit of engineering, uh, prowess and some good machinery- Yeah. You can, you can make magic happen, and that’s what CNC OnSite is doing. So that, that’s really amazing that, uh, you’re starting to get more adoption of that on, on the blade root inserts. I know across the United States there’s all kinds of issues, and you’re proving it out.
I think the adoption rate in America and all over is gonna really step up. Now, uh, you always have some cool new project, sort of top secret. What are you working on that the world needs to know about?
Søren Kellenberger: Yeah. W- I mean, we are constantly, uh, [00:17:00]expanding our, our line of services. Uh, so- Sure … so we are just out there trying to listen to what kind of issues do we see in, in the industry-
Allen Hall 2025: Yeah
Søren Kellenberger: and how can that be fixed, uh, uptower. So, so some of the, the latest, uh, innovations we’ve been doing is a, a new machine on, um… to, to do shaft milling. Uh, so that c- that can be on generator shafts, uh, for instance. There are some machines out there, but we’ve decided to go, uh, against CNC control- Okay
because it gives us a lot of, uh, opportunities both on, on speed, uh, of the process. It’s a more safe, uh, way to, uh, to do it.
Allen Hall 2025: Sure.
Søren Kellenberger: And we can actually also do different, uh, shapes on the shaft, so, so we can do more advanced, uh, repairs. Okay. We, we don’t need to stick to a certain diameter all the way. Now we can, we can mo- make grooves, and we can do, uh- Really?
all sort of sorts of stuff, uh- Oh … along that process because it’s CNC controlled.
Allen Hall 2025: Oh, sure. Okay. Um, and- Boy, okay. That makes a lot of sense. So you can actually take a, a, a basic, [00:18:00] basic, basic design of a shaft and make modifications to it- Yeah … to extend the lifetime and make it work better.
Søren Kellenberger: Yes. So typically we would mill down, uh, the shaft and- Sure
install a sleeve- Sure … to recreate a, a bearing fit, for instance.
Allen Hall 2025: Right. Yeah.
Søren Kellenberger: But we have possibilities to, uh, to create, um, grooves or anything that would do a stress relief or whatever you need, lubrication, or if you, if you want to do something, uh, afterwards, we, we can do that with, uh, with our machines.
Uh- Yeah. So yeah, we, we have some new machines for, for hollow shaft, uh, machining, so we can do stuff, uh, inside the main shaft, for instance. We can do stuff on the, the outside, as I mentioned on, on the generator shaft, but that could be on the gearbox as well. So- Sure … sometimes we see issues on the main shaft to, to gearbox, uh, connection.
Allen Hall 2025: Yeah.
Søren Kellenberger: We are able to, to fix, uh, those, uh, things uptower. Wow. And, uh, so yeah, lot of new, uh, stuff being, uh, developed.
Allen Hall 2025: That’s, that’s awesome.
Søren Kellenberger: [00:19:00] Yeah.
Allen Hall 2025: And I, I know you guys are busy, but- If somebody wants to get ahold of CNC Onsite and get work done this year, they better be making phone calls to you- … quickly. So I, I know your order book is filling up and you’re, you’re having to devote crews and machinery and time.
Yeah. How do people get ahold of you and get on that contact list and can start working the process?
Søren Kellenberger: I would say go into, uh, cnconsite.dk and, uh, there we have all our, our contacts. Uh, so just reach out. There’s a, yeah, formula you can, uh, fill in, uh, or you can find our direct contacts in our webpage, and, uh, then we can start looking at it.
So we are quite busy, but we are always- Yeah … open for, uh, discussions and, uh, yeah. That,
Allen Hall 2025: that’s a problem with being successful, is you’re just always busy running around trying to take care of problems, and that’s the thing, is that everybody I talk to that’s used CNC Onsite loves it-
Søren Kellenberger: Yeah …
Allen Hall 2025: and loves the process and loves the work you do.
So there’s gonna be a lot more phone calls and a lot more orders coming your way, and that’s- Yeah … that’s awesome. [00:20:00] Soren- Yeah … it’s so good to see you again and it’s so good to see you in person. Yeah. And congratulations on the promotion and everything that’s happening at CNC Onsite.
Søren Kellenberger: Thank you, Allen. It’s a pleasure.
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