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Vattenfall Ad, NextEra’s US Wind Strategy

The crew discusses Vattenfall’s ad featuring Samuel L. Jackson and explore NextEra Energy’s strategies amid regulatory changes. They also highlight the importance of inspections and CMS and Rosemary’s takeaway from an Australian wind conference.

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 FacebookYouTubeTwitterLinkedin 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!

Speaker: [00:00:00] 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 Saxu,, Phil Totaro, and Rosemary Barnes.

Speaker 2: Welcome to the Uptime Wind Energy Podcast from the Queen City, Charlotte.

North Carolina. I have Phil Totaro in California, Joel Saxum’s back in Texas, and Rosemary Barnes is here from the great country of Australia where Joel and Rosemary, along with Matthew Stead, will be rolling along the countryside visiting with. Wind turbine operators here soon, right

Speaker 3: Yeah, so the, the 11th through the 14th, uh, we’re gonna be jumping down to Melbourne because of course that’s, that’s wind central for operators and, uh, ISPs in Australia.

And we’re gonna be talking about all kinds of stuff with, uh, anybody that listen to us talk. So if you’re listening here, uh, and you’re in [00:01:00] Australia, connect up, uh, joel.saxo at uh, wg lightning.com. Uh, we’ll get some meetings set ’cause we want to, we want to hear what issues are happening down there, right?

What can we help with? What can we solve? Of course, Alan and I on the lightning side here, Rosemary is an independent expert engineer for you name it, in turbines. Uh, and our friend Matthew Stat over at iLogic Ping in the CMS space. And amongst the three of us, we also have a huge network, right? So if we’re, if we’re, if we getting into conversation, getting a chance to chat, tell us what.

You got for problems and we’ll help you solve ’em. So we’ll be down there the 11th or the 14th of August. Uh, reach out.

Speaker 2: Yeah, so there’s a lot happening in Australia at the minute. It’s starting to come out a winter, getting into blade repair season that is, uh, about to fire up in Australia. A lot going on around the world.

And today is Wednesday when we’re recording. And this is the day where Vattenfall released their Samuel L. Jackson. Add, it’s about a minute long [00:02:00] and you see Samuel L out on the shoreline with a bag of what? Seaweed chips. Joel, is that what they are? Or crackers of some sort?

Speaker 3: Yeah, a hundred percent. I gotta be, I’ll be a little bit, little honest with you.

I had some of those, not the same ones, not the Vattenfall ones, but I had some the other day just to try ’em out. They’re not my flavor. I’m gonna be honest with you. Don’t they just taste like sea salt? They taste like seaweed.

Speaker 2: That’s what it is.

Speaker 3: I know, but they’re, they’re not that awesome.

Speaker 2: But these, uh, crackers were the output of the seaweed and all the things growing around the offshore wind turbines.

I, I assume it’s just seaweed, right, Joel? It’s not anything else but seaweed. There’s no fish involved in that. It’s kelp. But see, like kelp, so

Speaker 3: like offshore kelp farming is a complete industry. Right. It’s just like offshore fish farming. They put these lines out, it grows on the lines, and then they pull it in and they harvest it.

This is a regular thing, however, having infrastructure out in the water, IE turbine foundations helps with all of these things. It’s structure there that protects ’em from, um, [00:03:00] currents and it, and it’s also things to hook lines too. So there’s a. There’s a symbiosis of offshore wind farms and the kelp farming community, and they’re showcasing this in the VA Vattenfall ad, kind of showing the value add of turbines of outside of all of the decarbonization of the grid and things we’re doing for renewable energies.

There’s also things in the, uh, blue economy, blue economy is the term for like ocean.

Speaker 2: There was a lot blue with that ad and it had nothing to do with the ocean. We just played it for rosemary, the unedited version or the un bleep version. Rosemary, what did you think of that ad?

Speaker 4: I really liked the video and what made, what was most amusing to me was imagining the pitch meeting at, you know, like a, some boardroom in Sweden.

Somebody had to pitch that video. Not only selecting Samuel Jackson, I, it’s not, doesn’t immediately come to mind when I think of wind energy and yeah, I mean, people will have to watch a video for themselves to see why I think that’s so funny. But definitely well [00:04:00] worth that minute or so of your life that that will take up.

Speaker 2: Well, is it, is it something that American Clean power should have done about six weeks ago? I just thought it was odd that Vattenfall was the one to pick up the baton and run with it instead of who, who we would normally think as being the thought leader in the United States. American clean power.

Speaker 3: I was thinking about a CP back when that was happening, and I, and I thought, what, what’s, what’s their response gonna be?

And their response was, we put out a statement. Okay. What does that do? Like, what’s the point here? Like you’re putting out a statement like, I, I don’t know. What’s that gonna accomplish? What are you gonna do with this? What is the action out of it? What is the, where are you, uh, standing up on a soapbox or like trying to get something changed?

Like, it, it does nothing for me.

Speaker 4: Yeah. I, I imagine a CP would be too worried about offending somebody with that ad. I, I would find it actually more surprising to come from them than, than from Sweden or, um, yeah, any other country. [00:05:00] But also, I don’t know, I don’t, uh, I don’t see a lot of impact from a CP and maybe it’s just, you know, obviously they’re not my organization.

I’m not, I’m not in the us I’m not doing a lot of work in the US so, um, I’m probably out of the loop. But, you know, the events don’t seem particularly, uh, I don’t know, I don’t come away energized like I do when I go to a lot of European events and our own events that we do in, in Melbourne. I was also at another really great one in Australia last week, uh, about renewables and agriculture, and that was fantastically energizing with a totally, uh, diverse group of people from all kinds of backgrounds, sharing ideas and actually, um, you know, like raising problems that need to be solved and figuring out the ideas to do it.

People sharing success stories. It was, you know, like a, it was a conference that is. Like, that’s the reason why conferences should exist for that sort of thing. I met so many interesting people, some of [00:06:00] who I really want to get on the show to talk about things like, you know, what’s it actually like to have a wind farm built in, um, built through your property or transmission.

Um, and then yeah, as well as. You know, there was a dairy farmer who had a couple of micro wind turbines on her site, uh, for example, along with lots of people with solar power and batteries. And, um, yeah, I even visited a, a piggery that’s got biogas recovery and, uh, using that to power the, um, the pig sheds.

So it’s kind of like circular. Um, so much cool

Speaker 3: stuff there. Did you refer to the pig farm as a piggery?

Speaker 4: Yeah.

Speaker 3: I wanna make sure I got that correct.

Speaker 4: Is it

Speaker 3: what, not what do you call pig farms? What do you call pig farms? Pig farm. That you bring up. A good point there, because this, this happens to us in the states sometimes, like if you go to the same conferences, for the most part you see the same people at the same conferences.

You have a lot of the same conversations. It’s of course great to catch up. I’m talking, I’m talking from the. From, you know, the, the, the, the commercial role. It’s of course great [00:07:00] to catch up with people and have touch points and have your meetings ’cause everybody’s in the same spot. But it’s pretty rare anymore, like say in the wind industry, at least in the United States, that you go to an event and you leave there and you’re like, oh, I got all these.

These new people to talk to and I got all this new information and like this new technology, this new innovation, like that doesn’t happen that much. But I will, I’m gonna go back to what you said. When I go to win Europe and when I go to Hamburg, like I do leave those events feeling a little bit more like that because more it seems like more things, new people, new ideas, different ideas, different people.

Um, I don’t know. I, I mean, Alan, do you feel the same way?

Speaker 2: I enjoyed the event up in Canada. I went about a year and a half ago, just because it was different. New people, new concepts, new ideas, different approaches. Hamburg was the same way. And the Australia event was very similar to that, just really different approaches to a difficult problem as an engineer.

I love to hear that. And Rosemary, [00:08:00] I know you like to pick up all those new technology pieces. Was there anything good on the technology front at that conference?

Speaker 4: Uh, there wasn’t so much, uh, like new technology, but people using technology definitely. And just some, um, like annoying obstacles to using it well, but the most interesting thing for me and what I think that other.

Conferences can learn from. It’s like you, you guys are probably the same as me, where every conference you go to these days, they talk a lot, a lot, a lot about social license, community acceptance for new projects, and everybody is very sincere in believing that this is an important problem that the industry needs to solve.

Especially, you know, we’re developing new wind farms and also transmission, but I just hear the same, you know, the same executives saying over and over again how important it is. I don’t hear anything new ever. At this conference? Yeah. It just actually included people who have been through this process.

Like I talked to one guy who has five wind farms on his side. He’s like, it’s great. I love having the wind [00:09:00] farms, but gee, the construction process was a, a pain and they did some really annoying things. And you know, that’s the, that’s the people that we need to get, um, into the other kinds of conferences where the executives go to.

Like you don’t, you can bring the right people that you want to your conferences. You know, you don’t just have to just see who comes based on ticket sales. You can say, Hey, we wanna talk about community acceptance. We need to bring some people from rural communities that express, you know, all sorts of different problems so that executives and professionals can hear those problems.

And then, you know, like. We’re engineers. We’d love nothing more than to know about a problem and then solve it.

Speaker 3: I think it’s, that’s interesting too, Rosemary, when I went down to the Texas Senate and, uh, testified here back two, three months ago, I got to connect with a lot of people that I normally would never run into.

Some of them were landowners from out in West Texas and stuff, and they were talking about the benefits and like how things actually happen as a landowner and from our, from [00:10:00] basically most people in the industry, unless you’re a psych supervisor or a wind tech. You don’t actually run into these people that are, you know, regularly affected or regularly deal with these things day to day.

So I think it’s important to get their, their opinions, their thoughts on, you know, as affected landowners or non-affected landowners, right? To, to hear these people out. But it’s hard to get that, um. That audience? Correct? Like a, from an industry standpoint,

Speaker 2: are you worried about unexpected blade root failures and the high cost of repairs?

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Field tested on over 3000 blades. It’s proven reliability at your fingertips. Choose Eco Pitch for peace of mind. Contact [00:11:00] Onyx Insight today to schedule your demo of Eco Pitch and experience the future of blade monitoring. Well some recent news from Next era. And as we all know, next era is the largest player in renewable energy in the United States.

And despite widespread. Industry concerns, uh, NextEra’s Energy’s executives, uh, are talking pretty optimistically about the next couple of years. On their second quarter earnings call, CEO. John Ketchum described the Trump administration’s one big, beautiful bill as tough but constructive for renewables.

Noting also that they have safe harbored enough equipment to get through about 2029. And I think Joel, what NextEra is planning to do is to meet the minimum criteria like Phil was talking about last week and. Qualify for PTC on some level. Maybe not at maximum, but at least in in part, which would [00:12:00]keep the projects rolling.

The safe harboring NextEra may be a little bit different than a lot of other operators. We have talked to operators that do have safe harbored turbines. There’s also a lot of operators that don’t, or that are just receiving turbines that are gonna be a little bit in trouble. The big players can win out because they can drive the demand for cranes and all the construction crews to help them first, the middle tier and the lower tier.

In terms of size, you’re gonna have trouble, right?

Speaker 3: Yeah. Basically, what you’re looking at here is NextEra, and this is not a new strategy for them. This is a NextEra regular. Operations as usual, right? They’re, if you look at their development and construction timelines as a Gantt chart across all projects, it is a lot of simultaneous operations, right?

So they’re starting one here. That one’s gonna start here and run to here. This one’s gonna start here, run to here. So like there’s, there’s not just one construction project going, because NextEra has the, the finances, the horsepower, the people, the [00:13:00] project managers, the, you know, and they have because they are who they are.

They have. The right hand of ge, they sell, they use a lot of GE turbines, so they have the forceful thing on ge and they have, like you said, down the ability to lock up EPC contractors for a long time and lock up cranes for a long time. So when everybody now here is with these new regulations coming into place, is scrambling to get things done.

The big boys, the, the next heirs in the room, they’re sitting in a pretty good spot because, um, if you’re looking at, you know, 2029 as the next possible administration change, like they’re gonna be good through 2029 here in, in the bullet points of what we’re talking about, they’ve signed 3.2 gig gigawatts of new contracts since April.

Now that’s probably across renewables. That’s not just wind. But 3.2 gigawatts. That is a massive amount of projects, right? That’s 3 30, 200 megawatts. Like if that was just turbines, that’s 1500 turbines, 1400 turbines. So, and that’s since April, right? We’re talking in the last three [00:14:00] months. It is going to be a squeeze for resources, especially with a, like the next of the world is gobbling up what they can, um.

I believe that you’ll see a very, it’s gonna be very hard to find a crane come October, November of this year.

Speaker 2: Phil, what are they doing on the financial side to hedge their bets a little bit? Are they, uh, planning projects a little bit differently? Are they, uh, going to be looking for a little investment to come in to.

Back fund, uh, the construction projects to provide additional funding to, to get the cranes on site. Cranes are gonna become a premium product here in a a couple of weeks. It seems like NextEra does have the way to do it, but they also are trying to de-risk projects from what I’ve seen lately.

Speaker 5: Is, is that the move?

Yes. And they’ve, they’ve already done a few things that are smart, as Joel talked about. One is that they’ve already safe harbored a lot, and the reason that that’s important is with the proposed changes to Safe Harbor. Uh. [00:15:00] It’s necessarily going to make it harder for developers to comply with startup construction.

So next era is ahead of the curve. With this, everybody else is gonna be scrambling to catch up. And not only are cranes gonna be in demand, but the OEMs are all gonna be, you know, in demand with pretty full order books here for the next few years, uh, assuming they can actually deliver turbines. To be safe harbored before the IRS rules change.

The problem with that now is we probably have less than six months because these IRS rules are gonna be changed probably by the end of the year. If you haven’t gotten your safe harbor in place already and you can’t guarantee that you’re gonna be able to physically receive the turbines. ’cause normally the safe harbor kicks in.

You spend, you know, the 5% of the total project CapEx, you actually have to receive the equipment. And if you can’t do that, if, if the OEMs can’t, [00:16:00]uh, supply you with equipment by the end of this year, which again is when we’re expecting these IRS rules to change, you’re, you’re pretty much done. And it goes back to what you’re saying before about, you know, what the heck is a CP doing?

This is supposed to be the lobby group that’s supposed to be facilitating the growth of the industry, or at least the, the stability of the industry and prevention of, of our decline. Um, you know, a rising tide is not lifting all boats here. They’re, I don’t know what the hell they’re doing while the rest of us are out here in the field trying to.

You know, steel in the ground.

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Visit eLog [00:17:00] ping.com and take control of your turbine’s health today. Joel and I just concluded another webinar with Skys specs, and we’ve been doing monthly webinars for, what, five or six months at this point, Joel. They’re really interesting changing subjects, all about how operators can save a ton of cash and o and m as we talked

Speaker 3: about in the last few weeks with regulation changes and stuff here, we’re gonna have a different reality in, in what the wind world is here in the United States shortly.

Um. Of course globally it’s, everything’s changing as well, but we have something massive coming towards us. So you need to change your o and m attitudes, your o and m thought processes, uh, whether it’s innovation, whether it is a different way of looking at things. Like the old idea of just kinda like, ah, we’ll just manage these things and we’ll kind of do it.

This is status quo and it’s not gonna work anymore. Uh, and that’s one of the cool things that we’ve had on those skys specs, webinars, we’ve had a lot of. Guests from the industry, right? So people that [00:18:00] are from operators, we’ve had subject matter experts. Of course, some internal skys specs, people that know their solutions really well.

Uh, but I think one of the differences there with the Skys specs team is, uh, people know them as the inspection. Gurus, right? Uh, and they do have massive market penetration for inspections. However, there’s a lot of other things that they do there with repair vendor management. So they have their hands in with the ISPs helping, helping customers out.

They also have, um, you know, CMS monitoring and SCADA monitoring, performance monitoring. Now you’re looking at financial asset modeling. Um, so there’s a lot of intelligent ways, uh, that they’re helping customers. Cut their o and m budgets down.

Speaker 2: And we referenced Phil today during that webinar because the price point came up about what the average spend is per turbine for maintenance.

I, I, Joel, it’s roughly, or Phil, it’s roughly 50,000. Dollars per turbine per year. That was a rough number that I remember.

Speaker 5: It’s, [00:19:00] yeah, it’s a little bit up from that now. It’s now at around, um, 54,500, let’s call it. Um, but there, the, the thing that concerns. Us at Intel store with that kind of data is that you’re seeing more projects have significant overages, um, because they’ve, they may have budgeted, let’s say seven or eight or 10 million a year, and they’re having to spend more than what they thought just to get, um, you know, cat four and five repairs done and all the other mechanical systems and, and whatever else they need to do.

Um. Particularly in light of this whole change in the PTC, you’re, you’re now gonna see everybody having to be more, um, resource efficient, time efficient, cost efficient with what they have and the budget that they have for maintenance. If they’re not gonna be able to be as dependent on P TT C revenue as, as they have [00:20:00] been in the past, so.

There, everybody’s gonna have to, you know, really be on point and, and potentially slim down some of these budgets and, and some of these big overages. And if inspection is, is gonna help facilitate, you know, early detection. Um, if CMS is gonna help facilitate early detection of an issue before it escalates into a CAT four or five.

You need to take advantage of that.

Speaker 3: Yeah. I think this, this is a, so it’s a nasty little storm, right? Because a year and a half, two years ago, we were talking about this trend that we were starting to see of the operators taking, like the, taking management of the turbines in-house, right? Doing things in-house or, or getting an ISP.

They’re getting rid of the OEMs and the reason they’re getting rid of the OEMs, partially, even some of some places we hear about the OEMs are like, Hey, we don’t want this one anymore. We’re done. What we’re seeing now is this. This is why, what. Where these overages are coming from, that Phil’s talking about.

Some of these, not all, of course, this is, none of these are hard, fast rules, but [00:21:00] some of them are coming from the fact that you had an OEM that was managing, or pseudo managing this thing, you know, up against a contract to just barely try to avoid paying lds. And then all of a sudden that end of warranty, end of FSA, it got handed back to the owner and the owner’s like, what the, what did I just inherit?

What do I got going on here? And I, and then they had to fix all these problems and get this thing back up to snuff. So the o and m costs are skyrocketing ’cause they’re trying to get back in front of ’em. They realized that they want to be proactive, but they can’t even be proactive ’cause they have to fix the reactive stuff first.

And. And now like, like you said, like doing those webinars with Skyspace, we’re trying to introduce people to tools to help them out as they go along, to be resource efficient. Plan your inspection, uh, inspection and repair and maintenance seasons holistically across your fleet with real data. Like do these things ’cause there’s, there’s digital ways and innovative ways to do this stuff better than managing things on spreadsheets.

Speaker 2: No, and I think as we go forward over the next [00:22:00] six months to a year. There’s gonna be a lot of, uh, controls on o and m. Budgets and asset managers are gonna be asked to constrict their budgets. If you start running Phil’s number here on a hundred turbine farm it, you’re spending a little over $5 million a year on general o and m.

If you can cut that by 10%, that’s a half million dollars in savings. That’s a huge amount, and I think a lot of operators today. Can get to that 10% number, but they’re gonna need to bring in a couple of the tools, the Horizon CMS system, a, a lot of the smarter technology that is out there that hasn’t been implemented so much because things were good.

Are now gonna get a second look. And the, the list of attendees during the Sky Specs webinar today was. Eye-opening. Like I know that person, I know that person, site supervisor, asset manager. They are [00:23:00] actively engaging now with solutions. Strike tape being one of ’em, talking to in store, being in another, that is going to change the game.

So we’re gonna get leaner and meaner clearly. But at that’s, I think a lot of operations are just starting to figure this out, that they, they need to get a hold of some help. And that help is there. That help has been there for the last couple of years and has been honed and it’s ready to go into action.

I, I think that was one of the, the leading points today with the Horizon CMS system was that system is actively working and actively saving operators a ton of money. And if you’re not onto that train yet, you need to hop on. Now

Speaker 3: we were talking with, uh, Ben Rie from Sky Specs. One of, one of their products has got 20 gigawatts underneath it already.

That’s just one of their monitoring

Speaker 2: products. Like they, it, it’s there. It’s not new. It’s been there, it’s been vetted. You may not be familiar with it, but that’s [00:24:00] the point of the Sky Spec webinars. That’s the point of the podcast. And we were just talking to Jeremy Hanks with C-I-C-N-D-T, who was in Australia at the conference and is a great person.

I love talking to him ’cause he’s so full of technology and knowledge. He was also saying he’s getting flooded with requests to start looking at blades from an ultrasonic test standpoint to do NDT work because a lot of operators are starting to realize I need to validate a repair that’s been done. I don’t want to pay for this twice.

I need to take a quick look at a blade that’s on the ground before I install it. ’cause his point, and you’ll see this in the, in the podcast that comes out, which is there’s a lot of safe harbor blades that are broken. That have been under floods or been damaged in transport, that need to be looked at before you hang them to save yourself millions of dollars on a new installation.

I know we’re all gonna go crazy on installs, but boy, there’s a lot of money on the table that could be saved right now. Joel,

Speaker 3: this is a full circle conversation because why does, why does the [00:25:00] podcast exist? Why does the Uptime podcast exist? I don’t know, Rosemary, maybe Rosemary knows, but the idea here is, is that we can, we can become a hub.

We have become a hub for solutions innovation, lowering LCOE, lowering budgets and incre. Like that’s what we want to do here. We wanna help this industry thrive. And it we, we we’re really lucky to be honest with you, to have the conversations that we get to have with people all around the world about what are your problems for one, and then the people that have the solutions, what are your solutions?

What do you got going on? Like when we do our. Uptime spotlights. We have some of the best and brightest people on to solve these problems. Like a Jeremy Hanks that’s gonna be on next week. He’s the best guy in NDT in composites I’ve ever met. I mean, he’s worked on spaceships and fighter jets and race teams and F1 cars and all kinds of stuff.

So the horsepower and the skills and the innovation, the technology, it’s here. You just need to engage, right? If you’ve got [00:26:00] problems, call us. We’ll help you point you the right way. Hey, we have this issue,

Speaker 2: and that’s the point of of this discussion is, uh, if you don’t know where to go. Reach out to the podcast.

That is the whole point. It’s a totally free service. We do not charge for this. You can call Phil anytime. He’ll give you some insight. If you call Joel up, he will connect you. If you get Rosemary on the horn, she’ll do you blade analysis probably for free, right Rosemary? So it, it is a huge family that we put together over time, over time.

We do know who’s doing what and why they’re doing it, and who has the technology. There is a lot of savings to be had, and I think this is the moment everybody to go after it and grow this industry. Screw what Trump’s talking about. This industry’s gonna be here long after he’s gone. Focus everybody. Deep breath and focus.

I think that’s the important takeaway from, at least from this week for me,

Speaker 3: mother Farms. This is, um, this is actually time. Okay. So [00:27:00] the wind farm of the week, this week is actually a wind farm cluster of the week, the Tofa wind cluster. And it’s interesting that this, this, ’cause this was planned before the last conversation we just had.

Um, but this is a wind cluster in southern Spain, so near the Iberian Peninsula there. And why it became the Wind Farm of the Week is a little bit different than I normally am looking at things in kind of a community impact way and stuff, but I wanted to look at a technical issue. Um, and the technical issue there.

This wind farm cluster has been there for a long time, but they’re in the process of taking a whole bunch of old turbines, repowering them with new turbines, uh, that are much larger, right? Because some of these turbines are only like 300 kilowatts at this existing wind farm in the, in the, uh, the tar wind cluster.

And they’re repowering it with. These massive Nordics, N one 50 fives and N one 30 threes that are 4.8, 5.5, 5.7 megawatts. I love it. Exactly. So this is where the cool repower, um, innovation and technology [00:28:00] thing comes into play because Southern Spain, if you don’t know about Southern Spain, bad light. So they, those turbines that are there have been getting beat up by lightning.

They have a compounding effect with the sea salt spray and the fog and then, and the moisture on the blades and storms rolling through. But what they’ve done is they, they, this has been a testing ground for all kinds of different LPS systems, um, in these smaller turbines. But now they’re replacing these smaller ones with beasts, right?

With 120 meter rotor monsters that are 200 meters up in the air. So they’re in this wind farm, they’re being smart, and they’re with these nordex turbines. They’re actually putting advanced LPS systems on them. Um. Before they get them up in the sky. And this is what we were talking about here in the States, we’re working on a bunch of repower projects and people are calling us to put strike tape on before they go up.

So it’s, it’s an intelligent way to do things. Um, so the wind farm of the week this week is that Rifa Wind cluster. It’s Axion Energy is a big part [00:29:00] of it. And there’s even some crazy old names in there. Alstom still owns some turbines in there, uh, which I don’t if you, if you’re not a wind turbine vet, you don’t, haven’t heard of Alstom in a while.

Uh, but it’s an interesting little place where the climate and geography drive innovation. Uh, this is a lightning prone zone, but of course there’s other areas in the world that are LEP issues, erosion problems, these kind of things that we can learn from, we can learn from each other, uh, and we can do better for the industry.

Just connect up, um, and we’ve got the technology. So the Tofa wind cluster in southern Spain, right down there in the Iberian Peninsula. You are the Wind Farm of the week.

Speaker 2: That’s gonna do it for this week’s Uptime Wind Energy Podcast. Join us next week where we’ll get updates on the latest in wind energy developments and properly President Trump.

So we’ll see you here next week on the Uptime Wind Energy [00:30:00]Podcast.

https://weatherguardwind.com/vattenfall-nextera-strategy/

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BladeBUG Tackles Serial Blade Defects with Robotics

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Weather Guard Lightning Tech

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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Bravery Meets Tragedy: An Unending Story

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Here’s a story:

He had 3 days left until graduation.

STEM School Highlands Ranch. May 7, 2019.

Kendrick Castillo was 18. A robotics student. College bound. Accepted into an engineering program. The final week of school felt like countdown, not crisis.

Then a weapon appeared inside a classroom.

Students froze.

Kendrick did not.

Witnesses say he moved instantly. He lunged toward the attacker. No hesitation. No calculation.

Two other students followed his lead.

Gunfire erupted.

Kendrick was fatally sh*t.

But his movement changed the room.

Classmates were able to tackle and restrain the attacker until authorities arrived. Investigators later stated that the confrontation disrupted the attack and likely prevented additional casualties.

In seconds, an 18-year-old made a decision most adults pray they never face.

Afterward, the silence was heavier than the noise.

At graduation, his name was called.

His diploma was awarded posthumously. The arena stood in collective applause. An empty seat. A cap and gown without the student inside it.

His robotics teammates remembered him as curious. Competitive. Kind. Someone who solved problems instead of avoiding them.

He had planned to build machines.

Instead, he built a moment.

A moment that classmates say gave them time.

Time to escape.

Two points:

If you can read this without tears welling up in your eyes, you’re a far more stoic person than I.

Since Big Money has made it impossible for the United States to implement the same common-sense gun laws that exist in the rest of the planet, this story will reduplicate itself into perpetuity.

Bravery Meets Tragedy: An Unending Story

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