Weather Guard Lightning Tech
Mingyang UK Manufacturing, RWE Cargo Drones
Register for the next SkySpecs Webinar! Allen, Joel, Rosemary, joined by Yolanda Padron, discuss RWE’s pilot project using drones to transport equipment uptower. Plus Mingyang has announced plans to invest $2B into a UK offshore wind manufacturing center. And Renvo’ article in PES Wind Magazine highlights the needs for a convenient spare parts marketplace in the wind industry.
Sign up now for Uptime Tech News, our weekly email update on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on Facebook, YouTube, Twitter, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary Barnes’ YouTube channel here. Have a question we can answer on the show? Email us!
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, Alan Hall, Joel Saxon, Phil Totaro, and Rosemary Barnes. Welcome to the Uptime Wind Energy Podcast. I’m your host, Alan Hall in the Queen city of Charlotte, North Carolina.
And I. Have everybody else on the podcast is in the same state. Rosemary is in Texas, in Houston, Texas. Joel’s in Austin, Texas, and our newest employee, Yolanda Barone, is in Austin, Texas. Yolanda, welcome to the podcast. You’re, uh, just joined us a couple of days ago and we’re super excited to have you.
There’s been a lot going on in the wind business. Uh, Rosemary’s actually over here for a conference and Joel’s been helping [00:01:00] out at that conference. Just so everybody knows, Yolanda’s gonna be our blade expert at Weather Guard helping us with a, a number of issues that operators have around the world, uh, for things that Rosie can’t take care of.
Call in Yolanda. So leading off this week, an interesting story from RWE and a big press release about it. Joel, uh, RDB has achieved a breakthrough in offshore wind logistics. By successfully testing cargo drones at its German wind farms, and, uh, the first time in German offshore airspace. Both long range autonomous drones and short distant cargo drones have been used in daily wind farm operations.
Uh, the pilot project demonstrated how different drone types can deliver spare parts, tools, and supplies to turbines. Uh, they were able to move up. About 10 kilograms, which is like roughly 25 pounds over about 40 kilometers. [00:02:00] That’s a pretty good rate. Uh, this is unique though to Europe because I think in the United States we’re not even allowed to do this, right?
Um, you can, it just depends on getting special permits. So it’s called a bv, LOS or BV loss, uh, beyond visual line of sight. Uh, so you can get, if you have specific, uh, software packages and you’re not over a major city and certain things, you can get those kind of, um, certificates from the FAA, but they’re not easy.
Uh, the, the cool thing about this is, I mean, let’s just put our technician hat on for a second. Even an onshore wind farm. I’m up tower and I go, oh, Alan and Rosemary and Yolanda and I are up tower and, and I go, who brought up the 10 millimeter socket? And none of us did. Now we have to draw short straws to see you, has to climb all the way down and get the 10 millimeter and come all the way back up.
Whereas with a drone, you could just fly up, land on the nelle and you have your tool, but it also means that you don’t have to [00:03:00] bring everything that you might conceivably need with you up there. So like when you are climbing towers every day, you’ve, you’re taking so much junk with you every time you go up, every time you go down and.
Like it sounds easy. Oh, they’ve got elevators in there. And that’s true. You don’t have to like put it in a backpack and climb up a ladder with it. Um, in towers that have a lift, but it’s still, once you get to the top of the lift, you still have to climb up a ladder to get into the nasal. And then if you’ve gotta get out into the hub.
And so you are still like picking up huge bags of stuff and um, yeah. Hauling them above your head. Always definitely exceeding the limit that you’ve just done your special training to promise that you’ll never lift more than 20 kilos. Um, you, yeah, it’s just like, it’s crazy the amount of stuff that you go schlep around with you because you don’t wanna have to go back down if you forget something.
So this means you can take up your toolkit for what you’re expected to need. Of course, you’ve got a lot of bulky safety [00:04:00] equipment that you have to take up ’cause you don’t know when you’re gonna need that. Um, but yeah, it’s gonna massively reduce the amount of stuff that you need to take up. Rosa, you bring up a lot of good points.
Right? And that’s just the, the daily active operations. And we’re, and we’re, I’m just thinking right now with Onshore Wind Farm, now go offshore and it’s, it’s boat landings into transition pieces. The, the amount of HSE risk just to transfer onto, uh, a tower or off of a tower to get components. It’s that much more complicated.
It’s that much more HSE risk. So. This makes absolute sense and these technologies have been kind of floating around for a while. Um, and one of the big things was, you know, of course it’s just the basics of drone stuff. So it’s can we safely lift this much, can we get the permits to lift this much?
Because like the CAA over in the EU there, they had a limit for a long time as well of, I think it was. 25 kilograms or something like that for like the whole drone setup couldn’t, it, couldn’t exceed that. Um, so you have to get certain permits [00:05:00] to do all these different things, but then it was, how do we safely precision land and take off and deliver the stuff?
So new advancements in, um, LOC localization, so like slam technologies, um, simultaneous location and mapping. So not just relying on GPS, but actually sensing what’s around you, whether it has, you know, a QR type. April, April tag codes that the drone camera follows and then kind of maps itself onto. Or if it’s has that, uh, the ability to see the blades and make sure it doesn’t run into them autonomously.
So the, the drone world has matured enough where this technology is like something that’s pretty normal now. You can see these things, drones, landing autonomously on boats that are driving by themselves and on the back of cars. Like it’s pretty cool stuff. Uh, but it was only gonna be so long until it made its way into industrial uses.
And this is a great one. You’re reducing risk, you’re reducing time, uh, saving money, all of the, you’re, you’re literally ticking [00:06:00] every box for operations. That makes this cool. I, I really like this. Uh, kudos to R to B for, for making this happen. Well, Yolanda, they should be doing this onshore too, right?
Because a lot of o and m buildings are not necessarily close to the wind farm. How many wind farms in Texas have we driven? Ooh. Five, 10 miles just to get to the turbine. Man, it would be a lot easier just to have a drone, wouldn’t it? Yeah, absolutely. I mean, it, it would save the team so much time and just so much effort.
Like Rosie was saying, to climb those turbines. The way we’re doing it now is with electric truck, right? Isn’t that, uh, RWE was doing a lot of the Ford, what’s the Ford Electric pickup truck, Joel? Wasn’t that RWE or was that Orad? That was Vestas. The Ford Lightning, we could just buy a bunch of cyber trucks and they could drive themselves out to the site, I suppose, if they can last through all the potholes on these sites.
That’s another thing you have to think about is technician time and the wear and tear on vehicles and stuff. If you at these o and m buildings, if you could, yeah, grab that piece of kit and, oh, I’m at, I’m at, uh, [00:07:00] tower, you know, WTG 17, but also the drone delivers you, your, your nuts and bolts or your package or whatever your name may or your lunch maybe.
That would be a good one too. Cup of coffee. What do I feel like the majority use of this drone technology will be for lunch? Hot lunch to the top of the tower. Come on. I’m sure I’ve told this story before, but I think it was New Brunswick when I climbed there, everybody had this specific electric crockpot that they would bring up with them and they would plug it in first thing, like as soon as they got up to the um, miss Cell, they would plug in their crockpot and then they would have a hot lunch.
And I had something that I had bought from the seven 11 ’cause that’s all there was in town. It was, it was miserable every single day. Here’s a question for you. I’m gonna ask this one. Maybe we should ask Alex Forer from Enertech this one. But, um, so as a, as a, um, a, a young worker in northern Wisconsin, I learned how to warm up my lunch and or breakfast on the intake manifold of a log [00:08:00] skidder by wrapping it in tinfoil and putting it into a certain puff spot in the motor.
Is there a thing in the tower up tower in the Nelle that gets hot enough? If you had a tinfoil wrapped, say a panini or something, that you could actually warm it up up there. The gearbox is warm. If it was running overnight, if the turbine was running overnight, you can sit some somewhere on the drive train.
It’s all pretty warm. That was my hot tip. When I, um, uh, when I was commissioning, uh, some turbines in Sweden, uh, the client demanded that I was, that we had an engineer there. Of the whole every day for the commissioning period of several months. So me and an electrical engineer traded off. He had actual work to do, but I was just there to satisfy the client.
So I just brought my laptop on and sat on the. Sat on the gearbox and um, I did get to see the Northern lights on some of those trips, so, you know, maybe it was worth it. Are you worried about unexpected blade root failures and the high cost of repairs? Meet eco Pitch by Onyx Insight. The standard in blade root monitoring Onyx iss [00:09:00] state-of-the-art sensor tracks blade root movement in real time, delivering continuous data to keep your wind farm running smoothly and efficiently.
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Well over in the uk, China’s Ming Yang Smart Energy, has announced plans to invest up to 1.5 billion pounds. That’s about $2 billion into a. Offshore wind turbine manufacturing facility and, and that’d be the UK’s first fully integrated offshore wind turbine manufacturing facility. Uh, a three phase project would provide up to 1500 new jobs and create an offshore wind hub.
Which would serve the UK and the rest of Europe. [00:10:00] Uh, phase one was supposed to include up to 750 million pounds to build a manufacturing facility for turbine to sell some blades with the first production planned in late 2028, and, and it would grow on from there. This is a big story in the UK and I’ve seen a little bit back and forth in editorials regarding whether the UK should allow Ming Yang to build this factory.
Obviously the, the Vestas of the world and Siemens ESAs would not be happy. Intercon Nordex would not be happy with this. And I would think that, uh, there’d be pressure on the UK government not to allow for a myriad of reasons. But, uh, a lot of articles more recently are. Proponents of this saying it will be the cheapest way to develop offshore wind in the UK and around Europe is to use a, a lower cost manufacturer like Min Yang and [00:11:00] Rosemary.
You probably have the most, uh, direct hand knowledge of Chinese manufacturing since you’ve been over in China. Looking at some of the manufacturing capabilities. What is the chance of this kind of facility being built in Scotland? Um, I’m not sure. I think that there’s two issues. The first is that the UK has or at least wants to have its own manufacturing capabilities.
Then there’s factor two, which is that they have legitimate, like they have real net zero goals that, you know, the government seems to be legitimately, um, trying to achieve. It’s a reverse situation of what happened 10, 20 years ago when, you know, wind energy came out of Europe. They developed the, the technology.
Yeah, there was a little bit of stuff going on in America too, but predominantly it was Europe that, you know, like developed, um, modern wind turbines as we know them today, and the manufacturing methods for the hard stuff like blades. [00:12:00] Um, and then all of the manufacturers, uh. Um, opened factories in China where at the time it was a lot cheaper to manufacture.
Um, and, you know, close to some other markets. China got really, really great at building wind turbines. Um, and then, you know, they started, um, developing their own companies, their own designs, but they had lots of labor that knew, knew how to do it ’cause they’d worked in the factories. You know, they, they had those skills.
So this is the opportunity to learn from, um, this company. Uh, you know, there’ll be UK workers working there and they’ll learn some things and there’ll be a bit of information sharing. It doesn’t even, you don’t even have to believe that China has surpassed the west in wind turbine technology, which I personally don’t believe that they have yet.
Um, but it is different and, you know, you can always learn something from, um, yeah, from, from getting a bit of a, you know. A little bit of diversity of ideas and, uh, going and seeing how somebody else does it, it’s [00:13:00]always gonna help. I would say China is not really open to sharing information. You, we know very little of how, uh, China operates as turbines or how they manufacture ’em, or what their performance is, or how they have done over long periods of time or.
What upgrades have been made and there’s just so many unknowns there. How can they avoid that if they, like, do you think the UK government is gonna let them staff it entirely by, um, temporary Chinese workers? Like there’s no way. I mean, and they definitely shouldn’t. So how can they possibly avoid the knowledge getting out if they have a factory that is stuffed by, um, UK.
Uh, people, then they’re gonna learn some things, and that’s, you know, if you, the more that they also, China is selling more and more turbines outside of China and they don’t usually maintain even, you know, do the full service agreement themselves. So people necessarily have to learn about it. They, they, there is no option if you wanna sell outside of China and manufacture outside of China, but that [00:14:00] knowledge is gonna get shared.
I mean, we all, we, we all learn that. 20 years ago, you know, is it knowledge worth having? I don’t know if we know that yet. I don’t think we can say that we, yes, yes or no. I don’t think we know that yet. I’ve got no doubt that it’s worth having. I think that this, this is an interesting point though with people, if you say the people thing, right, you’ve got, you know, they’re gonna, they’re saying three phase project, providing up to 1500 new jobs, and right now they’re looking at Inverness, which is way north in Scotland, and 1500 jobs up there would be man, huge for that, that local area.
And you’re, you’re correct in saying that there’s no way they’re gonna staff this with like, transient workers. So that leads me to, to this question. One of the reasons Ming people even look at a Ming Yang turbine, in theory it during a TSA or an RF PS style, time of the project is because of cost. Well, one of the reasons that the cost is way lower is because raw materials and manpower is way cheaper in China.
Well now if you have to get your raw materials to or [00:15:00] from, uh, you know, Northern Europe, into the, into uk and you’re paying local wages, are those turbines still gonna be as advantageously cheap? To even think about. Does that make sense? You’re right. But how could they possibly have got past the back of the envelope calculation for whether they should proceed if they weren’t sure that it was gonna be cheaper?
Yeah. And that, and that’s what I’m, that’s what I’m, yeah. What I’m, what I’m asking like in when they go to the uk, so we’ve heard the number before that if you were to buy a megawatt to megawatt onshore turbine, it’s, it was 30% of the cost of a Western one. And if you’re, and if that still is rings true, great, but there’s no way it’s still gonna be that cheap it, but it might only, it might be 70% of the cost of offshore turbine made by Siemens or Vestas.
That 30% savings might get just some people to pull the trigger. Well, it isn’t like a European manufacturers don’t have facilities. UK Vestas has the Isle of White facility. Siemens has a big Blade factory and Hull. Right. So [00:16:00]does GE have any facilities in the uk? Maybe there’s a research facility in the uk.
Rosemary, they had isle of some stuff on, um, on Southampton, uh, but not major manufacturing. We’ve talked about great British energy of them being the lead and, and developing energy in the uk. Why don’t they just start their own wind turbine manufacturing facility? They have the resources to do it. You could bring in people to, to obviously to help run it and, uh, use technology.
You know, we, we, even if you had a hire a, a vest as to come in and take over the plant and to do the day-to-day stuff. It’s all being built in country, which is ultimately the goal right? Is to try to get jobs in Scotland. Yeah. I mean the, the cool thing about this project, the way they’re proposing it is, is that it is going to be, um, fully integrated.
It’s going to be everything. It’s not gonna be a Blade factory and ne it’s gonna be everything in one spot. I think that’s great because that doesn’t exist elsewhere in the world. [00:17:00] Super plan. Um, but. What is the, what’s the catalyst here? What is the kickoff? What’s the trigger? How does Ming Yang end up doing this?
Is it, do they have to get an order for 400 megawatts of offshore turbine? Or they’re not just gonna build a, it’s not gonna be, if you build it, they will come. That’s not gonna happen. I thought, uh, they had been shortlisted for a couple of offshore projects. They’re shortlisted for Green volt. For green volt, but I thought there was a second one.
But Rosie, you, you would know this more than any of us. If, if someone says, if, uh, you now got the turbine supply agreement, great. Now you have to start a factory. Is that even plausible from turbine supply agreement to a maybe, I don’t know, 18 months, some year down the line, are you gonna have a fully integrated wind turbine manufacturing facility ready to kick out a turbine?
I know that, um, the general, you know, um, off the record opinion from people that I’ve talked to is that they’re totally doubtful whether it’s going to go ahead, that it just kind of keeps on kicking along as a [00:18:00] maybe indefinitely. It’s all global companies that are involved. Everyone’s gonna be once bitten, twice shy.
It’s, it’s hard to open. Wind turbine factories. I mean, something that I’ve worked on a fair bit in Australia with governments here that wanna have wind turbine manufacturing, but nobody wants to make sure that companies have certainty about their pipeline. And so no one wants to build a factory. Like you don’t even need to induce someone that much to build a factory.
Like you don’t need to give them huge tax, tax breaks or free land. Like all that stuff is is nice, but the critical thing that you have to have is. You need to know that you’re gonna be able to sell whatever you’re making. It’s gonna, you know, if you can make one every day, you need to be able to sell one every day.
You can’t, um, you know, sell one every day for eight months, and then you don’t know when your next project is gonna be. Like, that’s just, you need a decade’s worth of pipeline that’s pretty certain. And nowhere in the world really has that. But you know what, if there’s anywhere that has the, um, [00:19:00]like the size of the economy and the, you know, like tendency to place.
Big bets, it’s the Chinese government. And I wouldn’t be surprised if they, you know, saw it. If they think it’s strategic for them to have factories outside of China, then they will give whatever guarantees they need to make sure it happens. And that’s something that, like in the West, we’re not prepared to make those kind of commitments.
We’re gonna lose. And it’s not, it’s not by any means just wind energy. It’s everything that China is dominating at the moment. That’s how they do it. They do it by going big. Early, not worrying about losing money, not worrying about that. You know, 990 of the thousand startup companies are gonna fail. You know, they only care that they’re gonna have the 10, or, you know, the one or two left at the end.
And, um, they’re the only ones that have the, you know, that are playing that strategy. Yolanda, on the development side, the wind turbine history for Min Yang is not well known. How [00:20:00] much risk is that put into a project? And as a developer, what would you be thinking about if this factory is built? Is it something that you would try to mitigate with extra insurance, or could you even get insurance?
Would you look for additional funding for repairs that you just haven’t thought about? How would this even be approached without having a lot of information available to your teams? Right. You can’t really. See what the full risk profile of a project like this would be. Right. So it would be a little bit difficult to get the funding to, to put in all those values to a forecasting for a site.
So would the Ming Yang have to fund the project in a sense? Would they have to provide the financing for their own turbines or find someone that’ll provide the financing? I think, yeah. I think your traditional bank, your traditional banks would be hard to come by. Right. The people that are, that are.
Backstopping, all these other programs. I think that you would have to have someone in the [00:21:00] Chinese government, like Rosie was kind of mentioning, or Ming Yang themselves, offer the credit facility to get one of these things off the ground. ’cause insurance isn’t gonna play with it either. You gotta get the insurance and the finance to agree that the risk profile is low enough to make it happen.
And I don’t think you’re gonna have the traditional, like, like downtown London isn’t gonna jump on this. I think you’re gonna have to have some, someone from China or Minging themselves, backstop it. So we’re not talking about a million and a, or sorry, a billion and a half pounds. We’re now thinking it’s somewhere north of 5 billion pounds.
Yeah. Wouldn’t binging have to know that before they decided to move forward that it’s not one and a half, it’s 3, 4, 5 times that probably. But that goes right along with what Rosie said. They’re willing to, you’ve seen that, you’ve seen ’em take on industries elsewhere in Africa, in South America. Where they’re just pouring money into these places to get ’em off the ground and not worried about the losses as much.
’cause they know that [00:22:00] I, you say it way, way, said it way better than I did, Rosie. But they know they need to just kind of get their foot in the door and they’re gonna have to maybe lose some money. And take some risk by doing it themselves. 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.
Visit PES wind.com today. Well in this quarter’s, PES WIN Magazine, of which you can download yourself@pswin.com, a number of great articles. I’ve been reading one on Revo, which is a slightly different company. Joel and I were talking about it before we were recording today, and Joel described it as the eBay of wind turbines.
So I guess that’s sort of true, Joel, but [00:23:00] they connect sellers of decommissioned turbines with buyers and seeking basic cost effective solutions for repurposing those wind turbines, which is great. Uh, obviously Rosemary talks a lot about recycling of wind turbines. This is an easy way to do it, but it’s, it’s a difficult problem, right, trying to connect buyers.
Uh, uh, to sellers of older wind turbines. Where is this data? Where is this Amazon? Where is this eBay of spare parts? And then there’s the complications behind that, and the complications behind that being valuations of them. Um, how do we get the right people in, in line to make a a transaction happen? How do we get the logistics completed?
Is this a, you know, down to the serial numbers of certain things? Is it compatible with my wind farm? Do I need a different invert or are we at, you know, I mean there’s the basic questions. Is it 50 hertz or 60 hertz? Like, but that’s, those are things that not everybody’s thinking about. And me, uh, from a, my personal standpoint, I’ve been a part of some of these transactions from a, from a distance just [00:24:00] watching and, and seeing the moves.
And they get really complicated. And I think that’s what Revo ISS trying to solve here is access to these parts. Uh, access to the consultants that can, you know, help evaluate or value your equipment, and then tailor made support to making the transaction happen. And that’s what’s really, really needed in the marketplace because there is capability of this.
We heard from the insurance industry about how they can’t find obsolete parts, and we’ve heard from, uh, people that are extending, doing life asset extensions. And like right now, if you need a, I don’t know, send me on mm. 92 blade. Good luck. Unless you know the right people who know the right people who know the right people, you’re not gonna find it.
’cause it’s not like you can just go down to Home Depot and buy one. Uh, so that’s what Red Vote’s trying to do here is, um, solve some of those problems in the industry. And Yolanda, having worked for a large operator in the United States, is this something that even the larger operators could use? It does seem like it is difficult to find.
[00:25:00] Parts for older turbines or just to replace an older turbine? Yeah, absolutely. I think especially as operators start moving towards using ISPs a lot more, they can’t necessarily get things from the factory level that you would typically see from an OOEM, right? So even if you’re replacing something as small as like a LPS receptor, it’s really, there are parts that are really difficult to come by.
So if there could be an eBay type. Forum for people to get those things from site to site, that would definitely help out and help lessen the downtime that you have from just not having, uh, a part to replace on site in Rosemary. In Australia, there’s a lot of, uh, rural businesses, farms across the country.
They could buy a turbine for about 600,000 euros per megawatt. That’s a pretty good discount. It may make sense in a lot of smaller. Operations, not big industrial wind farms, but if you had a, a cattle farm or [00:26:00] mines. And mines. Yeah. Yeah. Mines are starting to generate more and more of their power from.
Solar because Australians are familiar with and comfortable with solar. Um, not so many mines getting into wind energy. There’s a few, there’s a gold mine, um, I think it’s called Agnew Gold Mine. And of course there’s recent news about Fortescue. They’re moving ahead on their plans to put a whole lot of, uh, wind power into Western Australia.
But smaller mines, I think it could make sense. I think one of the issues with, um, wind energy for mines is that. It’s not easy for them to get wind turbine techs out there, right? They do a lot of fly in, fly out work and um, they don’t wanna add probably another specialized kind of, um, employees. So some of these older wind turbines were much more the kind that any, you know, anybody who can maintain mine equipment would be able to maintain a wind turbine.
So I do think it makes a lot of sense. Well, you should check out the Revo article in PES Wind. Just go to ps wind.com. [00:27:00] And download your copy. So when this episode comes out, it will be next week. Uh, and so I’m saying this as next week, but future me, I will be in Copenhagen. So I’ll be visiting some, some local, uh, vendors, clients, friends, uh, the wind industry operators as a whole.
Uh, so reach out to me, uh, Joel dot saxon@wglightning.com or shoot me a text, uh, 832-593-2782. We’ll grab a cup of coffee, talk wind, uh, but I will be in Copenhagen all week. So, uh, hit me up. That wraps up another episode of the Uptime Wind Energy Podcast. If today’s discussion sparked any questions or ideas, we’d love to hear from you, and you can reach out to us on LinkedIn.
Even Yolanda, you can reach on LinkedIn, so don’t forget to subscribe. And if you found. Value in today’s conversation, please leave us a review. It really helps other wind energy professionals discover the show and we’ll catch you here next week on the Uptime Wind Energy [00:28:00] Podcast.
https://weatherguardwind.com/mingyang-rwe-drones/
Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage
This exclusive article originally appeared in PES Wind 4 – 2025 with the title, Operations take center stage in wind’s next chapter. It was written by Allen Hall and other members of the WeatherGuard Lightning Tech team.
As aging fleets, shrinking margins, and new policies reshape the wind sector, wind energy operations are in the spotlight. The industry’s next chapter will be defined not by capacity growth, but by operational excellence, where integrated, predictive maintenance turns data into decisions and reliability into profit.
Wind farm operations are undergoing a fundamental transformation. After hosting hundreds of conversations on the Uptime Wind Energy Podcast, I’ve witnessed a clear pattern: the most successful operators are abandoning reactive maintenance in favor of integrated, predictive strategies. This shift isn’t just about adopting new technologies; it’s about fundamentally rethinking how we manage aging assets in an era of tightening margins and expanding responsibilities.
The evidence was overwhelming at this year’s SkySpecs Customer Forum, where representatives from over 75% of US installed wind capacity gathered to share experiences and strategies. The consensus was clear: those who integrate monitoring, inspection, and repair into a cohesive operational strategy are achieving dramatic improvements in reliability and profitability.
Takeaway: These options have been available to wind energy operations for years; now, adoption is critical.
Why traditional approaches to wind farm operations are failing
Today’s wind operators face an unprecedented convergence of challenges. Fleets installed during the 2010-2015 boom are aging in unexpected ways, revealing design vulnerabilities no one anticipated. Meanwhile, the support infrastructure is crumbling; spare parts have become scarce, OEM support is limited, and insurance companies are tightening coverage just when operators need them most.
The situation is particularly acute following recent policy changes. The One Big Beautiful Bill in the United States has fundamentally altered the economic landscape. PTC farming is no longer viable; turbines must run longer and more reliably than ever before. Engineering teams, already stretched thin, are being asked to manage not just wind assets but solar and battery storage as well. The old playbook simply doesn’t work anymore.
Consider the scope of just one challenge: polyester blade failures. During our podcast conversation with Edo Kuipers of We4Ce, we learned that an estimated 30,000 to 40,000 blades worldwide are experiencing root bushing issues. ‘After a while, blades are simply flying off,’ Kuipers explained. The financial impact of a single blade failure can exceed €300,000 when you factor in replacement costs, lost production, and crane mobilization. Yet innovative repair solutions, like the one developed by We4Ce and CNC Onsite, can address the same problem for €40,000 if caught early. This pattern repeats across every major component. Gearbox failures that once required complete replacement can now be predicted months in advance. Lightning damage that previously caused catastrophic failures can be prevented with inexpensive upgrades and real-time monitoring. All these solutions are based on the principle that predicted maintenance is better than an expensive surprise.
Seeing problems before they happeny, and potential risks
The transformation begins with visibility. Modern monitoring systems reveal problems that traditional methods miss entirely. Eric van Genuchten of Sensing360 shared an eye-opening statistic on our podcast: ‘In planetary gearbox failures, they get 90%, so there’s still 10% of failures they cannot detect.’ That missing 10% represents the catastrophic failures that destroy budgets and production targets. Advanced monitoring technologies are filling these gaps. Sensing360’s fiber optic sensors, for example, detect minute deformations in steel components, revealing load imbalances and fatigue progression invisible to traditional monitoring. ‘We integrate our sensors in steel and make rotating equipment smarter,’ van Genuchten explained.
Other companies are deploying acoustic systems to identify blade delamination, oil analysis for gearbox health, and electrical signature analysis for generator issues. Each technology adds a piece to the puzzle, but the real value comes from integration. The impact of load monitoring alone can be transformative.
As van Genuchten explained, ‘Twenty percent more loading on a gearbox or on a bearing is half of your life. The other way around, twenty percent less loading is double your life.’ With proper monitoring, operators can optimize load distribution across their fleet, extending component life while maximizing production.
But monitoring without action is just expensive data collection. The most successful operators are those who’ve learned to translate sensor data into operational decisions. This requires not just technology but organizational change, breaking down silos between monitoring, maintenance, and management teams.
In Wind Energy Operations, Early intervention makes the million-dollar difference
The economics of early intervention are compelling across every component type. The blade root bushing example from We4Ce illustrates this perfectly. With their solution, early detection means replacing just 24-30 bushings in about 24 hours of drilling work. Wait, and you’re looking at 60+ bushings and 60 hours of work. Early detection doesn’t just prevent catastrophic failure; it makes repairs faster, cheaper, and more reliable.
This principle extends throughout the turbine. Early-stage bearing damage can be addressed through targeted lubrication or minor adjustments. Incipient electrical issues can be resolved with cleaning or connection tightening. Small blade surface cracks can be repaired in a few hours before they propagate into structural damage requiring weeks of work.
Leading operators are implementing tiered response protocols based on monitoring data. Critical issues trigger immediate intervention. Developing problems are scheduled for the next maintenance window. Minor issues are monitored and addressed during routine service. This systematic approach reduces both emergency repairs and unnecessary maintenance, optimizing resource allocation across the fleet.
Turning information into action
While monitoring generates data, platforms like SkySpecs’ Horizon transform that data into operational intelligence. Josh Goryl, SkySpecs’ Chief Revenue Officer, explained their evolution at the recent Customer Forum: ‘I think where we can help our customers is getting all that data into one place.
The game-changer is integration across data types. The company is working to combine performance data with CMS data to provide valuable insights into turbine health. This approach has been informed by operators across the world, who’ve discovered that integrated platforms deliver insights that siloed data can’t.
The platform approach also addresses the reality of shrinking engineering teams managing expanding portfolios. As Goryl noted, many wind engineers are now responsible for solar and battery storage assets as well. One platform managing multiple technologies through a unified interface becomes essential for operational efficiency.
The Integration Imperative for Wind Farm Operations
The most successful operators aren’t just adopting individual technologies; they’re integrating monitoring, inspection, and repair into a seamless operational system. This integration operates at multiple levels.
At the technical level, data from various monitoring systems feeds into unified platforms that provide comprehensive asset visibility. These platforms don’t just display data; they analyze patterns, predict failures, and generate work orders.
At the organizational level, integration means breaking down barriers between departments. This cross-functional collaboration transforms O&M from a cost center into a value driver. Building your improvement roadmap For operators ready to enhance their O&M approach, the path forward involves several key steps:
Assessing the Current State of your Wind Energy Operations
Document your maintenance costs, failure rates, and downtime patterns. Identify which problems consume the most resources and which assets are most critical to your wind farm operations.
Start with targeted pilots Rather than attempting wholesale transformation, begin with focused initiatives targeting your biggest pain points. Whether it’s blade monitoring, gearbox sensors, or repair innovations, starting with your largest issue will help you see the biggest benefit.
• Invest in integration, not just technology: the most sophisticated monitoring system is worthless if its data isn’t acted upon. Ensure your organization has the processes and culture to transform data into decisions – this is the first step to profitability in your wind farm operations.
Build partnerships, not just contracts: look for technology providers and service companies willing to share knowledge, not just deliver services. The goal is building capability, not dependency.
• Measure and iterate: track the impact of each initiative on your key performance indicators. Use lessons learned to refine your approach and guide future investments.
The competitive advantage
The wind industry has reached an inflection point. With increasingly large and complex turbines, monitoring needs to adapt with it. The era of flying blind is over.
In an industry where margins continue to compress and competition intensifies, operational excellence has become a key differentiator. Those who master the integration of monitoring, inspection, and repair will thrive. Those who cling to reactive maintenance face escalating costs and declining competitiveness.
The technology exists. The business case is proven. The early adopters are already reaping the benefits. The question isn’t whether to transform your O&M approach, but how quickly you can adapt to this new reality. In the race to operational excellence, the winners will be those who act decisively to embrace the efficiency revolution reshaping wind operations.
Unless otherwise noted, images here are from We4C Rotorblade Specialist.
Contact us for help understanding your lightning damage, future risks, and how to get more uptime from your equipment.
Download the full article from PES Wind here
Find a practical guide to solving lightning problems and filing better insurance claims here
Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage
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 YouTube, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!
Welcome to Uptime Spotlight, shining Light on Wind. Energy’s brightest innovators. This is the Progress Powering Tomorrow.
Allen Hall: 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.
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.
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