Weather Guard Lightning Tech

AC883 Solves the Spare Parts Crisis
Lars Bendsen joins the spotlight to discuss how AC883 helps operators source turbine parts to cut costs and reduce downtime. AC883 can offer faster response times and better pricing than manufacturers based in Europe. Lars shares how his company’s approach helps prevent extended turbine downtime by providing quick access to critical components.
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Sign up now for Uptime Tech News, our weekly email update on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on Facebook, YouTube, Twitter, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary Barnes’ YouTube channel here. Have a question we can answer on the show? Email us!
Allen Hall: In the wind industry, a turbine standing still often means one thing, waiting for parts that should be readily available. This week on the uptime spotlight, we’re joined by Lars Benson of AC 8 83, which is based in Canada. AC883 has direct connections to manufacturers in Denmark where most critical worm turbine components are actually produced Lars shares, house site operators can cut costs and dramatically reduce downtime by bypassing the OEM middleman and sourcing parts directly from the original suppliers.
Welcome to Uptime Spotlight, shining Light on wind Energy’s brightest innovators. This is the progress powering tomorrow.
Allen Hall: Lars, welcome back to the show. Thank you. Spare Parts is a huge issue all over the world, but it seems like in the US and Canada, there’s always a shortage. They’re looking for spare parts. They don’t know where to get them, and the easy answer has been to call the original equipment manufacturer in terms of the GE Vestus Siemens, cesa, Nordex, whoever that may be, and just to place a order.
There are other opportunities out there. What happens when a wind side in Texas just decides to buy from the wind turbine manufacturer? How much are they paying overpaying for that part?
Lars Bendsen: I can’t say exactly on on dollars and cents, but but we know the markup from the OEMs.
Then they’re not shy of earning money on that, those parts. And yeah, so it’s very simple. We can get those parts directly from Europe directly from the suppliers to the OEMs.
Allen Hall: Yeah. And if I’m an operator, and I haven’t been over to Denmark to look at the situation there, a significant number of critical parts are actually manufactured in Denmark or in the surrounding areas.
You have no way of knowing that if you own the turbine,
Lars Bendsen: that’s true. You don’t. Somehow the OEMs have been really good and keeping a bit of cloud cloudy around that area. It’s actually pretty simple. They all produced either in in Denmark and Germany for basically all turbines. GE turbines is a target turbine from Germany that that they bought back when.
So that’s why sim that’s a German turbine as well. It’s not a US turbine at all.
Allen Hall: And the supply chain has remained that way for a long time.
Lars Bendsen: It’s a BP parts. It’s standard parts. There’s no rocket sites in it. Of course, there’s some legacy some software parts and stuff that we could be desk, some, what we call it electronic boards, which software on, of course we can’t do that.
That’s fair enough, right? That’s actually where the OOM has its value. That’s totally good.
Joel Saxum: I think part of the reason that you see this, that gap there in the industry is the simple fact that, and I don’t take this as a slight Lars because I love your website and what you guys do for marketing and branding, but in that corner of the world, and Alan, you and I were just talking about this couple of German companies we’re talking about they’re not that good at global branding and global marketing.
As a unit like culturally, so you don’t see really what’s going on almost behind that curtain as an American, when you log in and go I need some breaks, or I need this, or whatever. You don’t see that manufacturer’s website pop up. You may see an AC 8 83 pop up that says, Hey we have we sales spare parts.
But you just don’t as an American and to be honest with you. Running around the United States talking to all these wind site operators, they’re so dang busy with their day-to-day life and solving the, putting out the fires and the problems that they have every day, that they don’t have time to go search for that stuff.
So what do they do? They just call their procurement or the person that they know and they say, Hey, get me this. And if they end up overpaying for. 10, 20, 50% or whatever. It got the turbine back up and runway because uptime is king. So what else are you guys doing to strategically work with your clients and your customers to make sure that they don’t have to do that?
Lars Bendsen: Generally speaking, I agree with larger countries let it be germinated. But the US and Big Canada they have such a big inner market. They’re horrible in doing export, generally speaking. They’re not good at it. They’re really good at producing stuff and doing the take care of their own stuff.
Denmark, I think it’s 97% is export or being produced in Denmark, something like that. Because we have five, 5 million people, there’s no inner market we need to get out there where the market, inner market in US and Canada and Germany is so big. You don’t, we don’t need export. We’re not real good at it.
And don’t call Canada US export. It’s not export, it’s the in the market. So far,
Allen Hall: the turnaround times from the OEMs tends to be slow if they have the part in stock and there’s so much demand at for some specific parts that they don’t always don’t have it sitting on a shelf to send to you, which is a huge problem.
So you have to develop a subsequent chain, a supply chain, and why not go right to the source? Which is gonna be in Denmark for the most part. Why not do that as to source the actual part instead of an imitation part or a refurbished part, which I’ve seen more of recently. You can actually get the real part.
Lars Bendsen: It’s still surprising me sometimes. We hadn’t known em last year. They just closed their warehouse for three months. We just closing them. We cannot supply it for three months. How’s that gonna work? This wasn’t a European summer thing, was it? No, that was gonna be six weeks. That’s only six weeks. No, it was exactly in the fall, I think it was.
And they just decided to close it for three months. And I don’t understand this, OEMs should earn $0 on the turbines itself. They’re earning money on the service and the parts look at the accounting on vest and seems real. They’re earning no money. It’s only on their aftermarket and vest, in all fairness, are extremely good at it.
Really good at it. They have 75% or whatever the accurate number is covered of the fleet with service and parts is great. So we are not hunting as much vessel because why would we find that needle in the haystack where you could say that Siemens and ge they have less percentage, way less, maybe half of that depending on countries, et cetera and areas.
But still, again, how can you allow yourself to just close your warehouse to three months?
Joel Saxum: That’s crazy. Do let me ask you something about that, Vesta the vests setup ’cause in my mind, okay. I worked with a Danish company, very process driven, very controlled. There was step changes in gates and, everything was mapped out very well in how the company operated.
So do you believe that the, one of the reasons that Vestas may have a really good control of spare parts inventory and the direct connection to those sites is because they sign those. 20, 25, even 30 year FSAs. Is it all based on this overarching business model that, that encompasses that and the others aren’t just, aren’t doing that?
Lars Bendsen: I don’t know. I think it’s I think everybody wants to do it. That’s just my 2 cents. I’m not an expert in that area, but my 2 cents is that vessel has the power to demand that. And they’re not selling any new wind farm without a service contract, whatever’s 5, 10, 15. They do not. Where some of the wind inside the smaller, they have less power.
The owners say, you know what, that’s all well and good, but then we’re not gonna buy your turbines. And then GE and Siemens has to cave in a little bit. That’s my 2 cents.
Joel Saxum: I think strategically like GE with having expanded in their service thing and then now changing it to the hub and spoke model, like I think that this is my 2 cents, right?
I think GE saw some bloat. In what was happening in service. And I’m not gonna say parts ’cause I don’t think that’s true, but service and this FSA and I think that GE is actually strategically pulling back from signing these FSAs. And because some of the stuff with, we’ve heard horror stories with, and this isn’t just ge, it’s all the OEMs with, liquidated damages, catching up with people and those kind of things because they don’t have access to spare parts.
So they don’t have access, they don’t have the service people to get out there quick enough. So it’s a, there’s a large problem in the industry and I would say that if you’re a wind farm operator or wind site supervisor, technician, whatever, it’s at some point in time, you’ve felt the pain of not having that spare part that you need to get your turbine up and running.
And that’s where a C 83 comes into play.
Lars Bendsen: Yeah, I agree, but I also believe that some some owners are too small that the OEMs even care. We have seen some horrible example that, you know. Care list. That sales person sold that wind farm. That’s it. He can care list and the aftermarket people sitting in Denmark and they are, they’re closing at four o’clock eastern as it’s four o’clock.
It’s not four 10. It’s four o’clock.
Joel Saxum: So if you’re in the central part of the United States, you need to be on the phone by 7:30 AM Otherwise you’re not getting your stuff.
Lars Bendsen: No. Or on Fridays is close by noon, so forget about it. You get an answering machine, so you can’t even call on Fridays.
So that happens. We have a policy, we pick, we always pick up the phone, we all always answer our emails. We don’t have an out on office, not on purpose. At least doesn’t exist so I think it’s more avail, be available and go the extra mile instead of just sitting for a number. There are might be two picture lenders.
Let’s take an assemble of that. There’s four different vendors, which the same A nine B number from Siemens. There are four different A nine B sorry, producer of a nine BXX, x. So you can pick the most expensive one. You can pick the cheapest one, pick whatever you want. And there’s probably a reason between something, a correlation between quality and price often this.
So yeah. It’s about knowing those manufacturers and have access to them. Yeah. And we are, I think we’re pretty good at it.
Joel Saxum: Yeah. As I’m gonna put my wind farm operator hat on for me that, that’s that triangle. Good. Fast and cheap. Pick two. I. That’s what I always look at.
Two outta three. Yeah. But having someone in the corner, like AC 80, 83 that knows, hey hey Lars, I need this part. Great. Okay. I can get it from one of these four people. Here’s the cost for all four of ’em. Here’s the quality of our opinion and the track record we’ve seen, and here’s the lead time.
’cause that’s always the big one. If it’s a reactive situation where I need a part now, which we hope we’re not doing as much reactive as proactive, but if it’s a reactive part and I need it now, I need to get that turbine back up and running. You guys have the answers to those questions.
Lars Bendsen: Yeah, I think I agree with you that’s the reactive part of it and that happens.
SC actually happens a lot and I think we are back to what you said around before, that everybody is so lean, that site manager don’t have that extra person to source those parts. And all of a sudden we have a turbine down, we are missing one animal meal for $500. How can that happen? And of course you could be unlucky as well.
I totally get that part. We are trying to be more proactive. So if we have a major owner that have 20 or 30 sites, because you see they use the same parts, all of them. So one, don’t, we bundle out procurement instead of taking one off all the time. We spending a ton of time with one off $500. Procurement and it takes too much time and it’s too expensive for everybody involved.
There are some suppliers now I got actually hit by it. Some suppliers in in Denmark now they have a minimum or a quantity, or you get a fee, extra fee on it. So you can order a one animal meter used as an example without, is a 250 or $300 fee on it for handling the order. We’ve seen that as well.
Joel Saxum: So reactive is a lot of where the market sits, but how are you guys working with customers to be more proactive in their strategies for spare parts?
Lars Bendsen: As in the back office say GaN, Sydney, et cetera, they’re extremely data driven. We can see the history of what had been quoted, what had been ordered, what pricing has been ordered, when was it, et cetera.
So we know the history. I said, why? We can see we are buying 40. Why do you buy one or two design? And even if that person cannot do it, we’re still gonna buy five or 10. So we have something that helps our what call it procurement power. We leave it un stock because we are trying to avoid, has too much in stock and we do not wanna have obsolete parts either.
So that’s the kind of the balance we have, we are finding.
Allen Hall: Lars, can you gimme a sense of what kind of parts you can acquire or from the original equipment manufacturer? In Denmark,
Lars Bendsen: we just set up a big agreement with one of the main the major filter suppliers. Now we have a nine p numbers for all fillers in the world and for western fillers where we have all fillers and it’s a fraction of the price we’re paying today.
Fraction, pit cylinders motors, gears, et cetera. We are staying away from major components. We’re staying away from from gear boxes, generators, habit supply, main shaft and bearings for simul because that’s the focal point. So that’s, we could do that. But gearbox, generators it’s not worthwhile for us to do it.
We don’t add any value. You could get that part. It’s just a part number. We can’t add any value at all. So decided of staying away from it. We don’t wanna take the risk for a small portion of dollars.
Allen Hall: And if I’m sitting at a wind site and I’m getting requests for a specific part, how does that process work?
So I’m calling Sydney at your site or go, or getting ahold of you on LinkedIn. Then how does that work? How does that procurement system work? How do you navigate that? Because it sounds like you have some of the parts sitting on the shelf. Some you have to go acquire and negotiate.
What’s that process look like?
Lars Bendsen: The process is that you’ll get an email we got your R fq, we’re working on it right now. You’ll get an email within an hour that we have. It don’t, we won’t leave you high and dry. We are responding and then we are gonna source it right off the bat. If you don’t have it, and within a day or two you will have an answer back with a, with the price and lead time.
Allen Hall: Okay. So that’s a really short response time because usually it takes several days to get someone to re return that phone call.
Lars Bendsen: Yeah, so that’s the thing. Availability is key, right? Availability to the parts availability is key and it goes for the parts as well. You said lead time? We get way short on lead time, but call the manufacturers directly.
Waste or,
Allen Hall: and the, obviously the equipment manufacturers must have stock on the shelf. They have to do that so that those parts do exist. We just didn’t know where to find them until we called AC 8 83.
Joel Saxum: That’s a story that you hear a lot in the United States, right? Again, Alan and I travel wood Farm.
Oh, these, there was some German guys here. There was some Danish guys here. It’s always German and Danish. We had to get these special bolts from Germany, or we had this. So now everybody has their own Danish guy that they can call Lars that person Yeah. That has the connections to, to the mainland, to the motherland that can get these things for ’em, because that’s the troubling part.
Like we said, you don’t have time to, procurement is tough. Strategic procurement is difficult. Even people that are doing procurement at a large scale in an organization, say you’re in the back office and you’re the procurement person. They’re dealing with so many things that to find this one part at one of these few manufacturers over in Denmark, that’s difficult.
So now you have every, everybody that’s listening here has the connection to that dane that has the connections over there and can get it done for ’em.
Allen Hall: One of the big criticism in the United States and Canada is that when anybody drives by a wind farm and turbines not operating.
It’s just, it’s a knock on the industry. And the most times that is occurring is because they’re waiting for a spare part, honestly. Real simple stuff. Filters, for example, is a good one, right? And parts that they can’t get the hold of, but they just don’t know how to acquire them. And now they’ll listen to the podcast.
This is the way to do it. You call ours, you call Sydney at AC eight eighty three and you get this process started and then at that same moment I know Sydney is really sharp. She’s gonna provide you the list of things you can get. So she, you tell her, Hey, I got a GE two X machine. She says here’s the list of parts we can get for you.
Wow. That just saved my life for most procurement people. And that’s a personal, Sidney is not your friend for life because she is saving you. A lot of money and a lot of time, and a lot of hassle, which is the point, right? This is why everybody goes to AC 83 because it’s simple, easy to get things done.
Lars, how does an operator a site supervisor, a procurement person, get a hold of you to start ordering some of their spare parts through AC883?
Lars Bendsen: You have a website, ac883.com or my email, lars@ac883.com
Allen Hall: And you can also reach Lars and AC 8 8 3 at contact at ac883.com. The website’s great, so get ahold of Lars, get ahold of Sydney, get your projects moving.
Again, Lars, thank you so much for being back on the program. We love having you. Thank you. Thanks.
https://weatherguardwind.com/ac883-spare-parts-crisis/
Renewable Energy
Pardalote Studies Australian Blade Erosion and Heat Fatigue
Pardalote Studies Australian Blade Erosion and Heat Fatigue
Rosemary Barnes, CEO and founder of Pardalote Consulting, joins to discuss their new grant-funded study of blade erosion and heat fatigue in Australia.
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 2025: Well, Rosemary, welcome back to the show.
Rosemary Barnes: Thanks, Allen. Great to be here. For, it’s been a while since we did one of these one-on-one episodes, like a, yeah, a proper, proper guest.
Allen Hall 2025: Well, this is kind of a celebratory episode because your company, Pardalote Consulting, has been awarded, uh, some funding from the Australian Capital Territory’s government for the Energy Innovation Fund.
Rosemary Barnes: It’s a really good program that the ACT government has to try and get energy innovation In the state. It’s not a state actually, it’s technically a territory. Little more than just Canberra, the city. Uh, but there are actually quite a few, like, really interesting energy-related companies here, partly ’cause of the, the fund I think helps, but also just tracing back like, [00:01:00] uh, y- you know, in the 20-teens, Australia had a really conservative government that hated renewable energy, and the ACT government had a commitment at that time to 100%, um, 100% renewable electricity for the, the government.
And that was one of the only programs that was resulting in a lot of, um, you know, clean energy projects being built, and one of the conditions that they put on that, uh, for people that would win PPAs with the ACT was that you had to have your headquarters in Canberra. So we’ve actually got quite a few, quite a few really cool, innovative companies out of here.
Um, like Neoen’s headquarters here. Windlab, uh, yeah, was, was founded here and still has a lot of people here. Pardalote obviously, and you know, a few other companies as well. So despite it being a small city of like, I don’t know, maybe it’s up to 400,000 or something people by now, um, yeah, there is actually quite a lot going on here for energy.
Allen Hall 2025: And the Energy Innovation Fund is funded by the wind and solar operators in the area, and your particular [00:02:00] effort has really global consequences. You’re focusing on two areas involving how wind turbines survive Australia, but more, uh, of relevance is to just really tough conditions which exist not just in Australia but around the world.
What two areas are you going to focus on?
Rosemary Barnes: Yeah. So the two focus areas are leading edge erosion and high temperature fatigue, which we can probably get into the definitions of those in a minute. But basically my, um– what led me to wanna have a project like this was that when I moved back to Australia in 2021, I– and I started working in O&M, uh, I noticed that the wind turbines that I would look at, the blades that I would look at here behaved really differently to the ones that I worked with overseas.
You know, es- especially with leading edge erosion, like often I would be doing a condition assessment of a, you know, a new wind farm. Um, might only have been operating for, you know, two years. That’s a pretty common time for people to get in and do a condition assessment [00:03:00] because their warranty period is about to end and they wanna, you know, make sure that everything is okay.
Um, and I would just notice that often, like 90, 100% of blades would already have bad erosion after just a couple of years, which is super-duper fast. And then there are some tools available to check, um, like what kind of erosion are you likely to experience on your site. Like is it a higher severity erosion site or a, a low severity one?
Um, and you basically, you know, the status quo globally is to just look at the annual rainfall, um, and the tip speed. And if you’ve got, you know, high for both of those, that’s a bad erosion site. And if you’ve got low for both of those, it’s a, a low erosion site. But when I plotted out the wind farms that I knew had really bad erosion problems onto, you know, a chart with those two axes, I just saw a random distribution of dots.
You know? Like, this was not– uh, this had no predictive value for Australian wind farms. And so that led me to believe that, okay, um, you know, things are a bit [00:04:00] different here. Makes sense, you know, most of the knowledge that we have about how wind turbines operate, it’s been developed and validated mostly in Northern Europe.
You know? Like it’s, it’s Denmark and the surrounding countries that had, like, the bulk of the early wind energy. First few decades of knowledge were, you know, were mostly there. Of course, there were some other, um, places that had wind turbines, but, you know, most of the The OEMs have been operating for decades, came from Denmark.
And I know when I lived in Denmark, the rain there is very different to the rain in Australia. So in Denmark, it’s basically always raining, right? Like, it’s just… Like, even if it’s not raining, you’re still gonna get wet when you go outside ’cause it’s just, like, the air has this just amazing ability to just hold onto moisture.
Um, but it’s very, very gentle. But, you know, over an entire year of most days having gentle rain, that adds up to a lot. Whereas in Australia, and especially if you go, like, north to Queensland, it rarely rains. It’s mostly just dry, and when it [00:05:00] does rain, it’s like a tap turns on, and I, I swear you will get bruised from the rain droplets hitting your skin.
You know, they just have so much energy in them. So I think that that i- you know, when you look at just the overall rainfall, you really hide something important about how erosion, um, can progress. Then, um, there’s other places in Australia that have very different characteristics. Again, they don’t have that kind of really intense rain but, you know, some of those sites are also having really bad erosion.
And so it just occurred to me, I did a lot of research, you know, into what’s going on and, you know, the academics are studying erosion a whole lot, and they’ve got, you know, a lot of standardized tests and, you know, products are developed according to these standardized tests. But the standardized tests don’t actually resemble reality, and especially they don’t resemble reality in Australia.
And so my client started asking me, “Okay, you know, the products that we have are, are terrible. We have to replace them every couple of years. It’s, um, causing big problems with also [00:06:00] the amount of energy that you’re losing.” One of the types of, um, leading-edge erosion or leading-edge problems that we have in Australia is that the, the coatings tend to peel off and make these, like, big flakes which will just massively disrupt the airflow, can cause y- you know, at least a few percent AEP loss, and maybe up to five.
And even worse than the AEP loss is the revenue loss because it affects it most at, you know, lower wind speeds. Um, you get a bigger hit than at rated wind speeds. So there’s a variety of problems going on with leading edges in Australia, which mean that I, I basically… My clients would ask, “What product should we put on to prevent having to, you know, constantly replace this?”
‘Cause it costs, like- you know, 30, $40,000 per turbine to replace the protection, not to mention, you know, one or two days of downtime. It’s expensive, and I basically, I didn’t have a good answer for them. What, what product should they put on? I don’t know. No, we, we don’t know. One, we don’t know what the [00:07:00] specific, um, characteristics are that are…
what the specific local environment, local conditions are that are accelerating leading-edge erosion, one. And two, all of the products tend to be tested around this, you know, there’s this protocol that academics have come up with, and they’ve kind of like assumed that this is representative of how things behave in the field, and it’s– I don’t think it’s particularly true anyway, but it’s especially not true in Australia.
There are a few companies that are testing to different standards. Um, definitely applaud them. But without knowing wha- what are the conditions truly like in Australia, uh, it’s really hard to advise, like, what kind of tests should you be demanding from a product you’re considering to be sure that you’re gonna put it on and not gonna be replacing it again in two years.
Allen Hall 2025: Because that’s really the trouble in Australia is when you get offered products They have been tested generally in somewhere in Europe and maybe in the United States, and then when they go to [00:08:00] Australia, it’s really unknown as to how those products will do, which is a huge risk for the Australian wind market as to what to choose, how to choose, is it– what’s real in terms of test data.
So now you’re gonna go out and do what? Are you gonna put sensors out by the wind farms? Are you gonna try to do more of a statistical summary of the actual environment around wind farms using existing data? What’s the approach here?
Rosemary Barnes: It’s all of the above, but the part that is supported by the grant is that we’re gonna have enough money to be able to buy some scientific-grade sensors and put them on, um, a sample of Australian wind farms.
So we’re gonna be looking at a lot more characteristics about the rain than simply is it raining now, you know, how many millimeters per hour. We’re also gonna be investigating, you know, every kind of characteristic of, of that, um, of that rain, um, including, yeah, like the, the energy that’s in it, for example.
A, a bunch of stuff. I won’t get into every single [00:09:00] parameter. Um, and you know, other things as well, like measuring UV, solar radiation, um, particles, because, you know, in Australia we have a lot of dirt roads, which I know is very common in wind farms around the world, but Australian dirt roa- roads are always dry and dusty, like 99% of the time, so that’s one of the things that y- you know, maybe that’s causing a difference.
Um, so basically putting sensors all over a bunch of wind turbines and then monitoring the erosion, um, a combination of some real-time monitoring and also looking at inspection, um, drone inspection images annually. We also have a- an option where we’ll just be using SCADA data and inspection images, so that’s like a lower cost version where we can combine that with the findings from the scientific-grade instrumented turbines to build up a picture of what types of conditions lead to accelerated erosion.[00:10:00]
Allen Hall 2025: So the SCADA data will, will have some information inside of it, you think, that, uh, will correlate to the weather outside?
Rosemary Barnes: It has some Additionally, we can look up, um, you know, just the weather data, like how many millimeters fell during which 15-minute interval throughout the day, what was the temperature.
SCADA will tell us also what the temperature was, um, what the speed of the turbine was, so you can calculate the tip speed, ’cause that’s an important thing. Um, yeah, so it’s, it’s two, it’s two tiers of data collection. The scientific grade sensors, as you can imagine, are, are really expensive and y- you know, the, the grant project has contributed a, a lot of funding, um, but it’s not enough to put those, yeah, put a little mini lab on top of every turbine across Australia, obviously.
So that we’re using s- doing selectively, and then we can increase the number of wind farms that are included in the study by just doing this, um, cheaper version of the SCADA [00:11:00] plus, uh, weather data that’s available.
Allen Hall 2025: So what are some of the risks on the temperature side for all the high-temperature regions of Australia that have wind turbines?
Clearly it’s generally warmer in Australia than it is in, in Scandinavia and Northern Europe. What kind of temperatures are we talking about on the ground?
Rosemary Barnes: Uh, well, temperatures here can get pretty close to 50 degrees. Um, and if you’ve ever been inside a wind turbine blade on a, even a mildly hot day, you’ll know that the temperature inside a wind turbine, and especially inside the blade, is much hotter than what it is, uh, what the ambient temperature is.
So this project is one– I’ve actually been talking about this project for, yeah, like over 10 years now. Ever since I started, I moved to Denmark, started working for a wind turbine manufacturer, I had done– I had just finished doing my PhD on composite materials, structural design, and analysis. So, um, yeah, very, very familiar with, [00:12:00] you know, how composite materials work and, in particular, the effect that temperature has on them.
I mean, like most materials, when composites get warmer, they get softer, and that is really important for a w- a wind turbine blade. You know, if it gets, um, less stiff, then you’re gonna get a lot more strain, and that is going to affect your fatigue behavior. Y- you know, fatigue is just the application of a little bit of, a small amount of strain.
It’s not gonna cause damage, but when you apply it millions, tens of millions of times, like you do in a, o- over a wind turbine’s operate, um, operating lifetime, then that builds up. And, you know, wind turbine blades are a very fatigue-driven design. Um, it’s one of the most important things to consider when you’re designing a wind turbine blade.
And so when I got to Denmark and I learned how materials are qualified and how the qualification is treated in the certification process, I just realized it’s not particularly conservative, and also that some of the assumptions that are made that [00:13:00] wo- again, they worked really well in more moderate climates where wind turbines have had most of their developmental history.
You know, it’s not such a big deal there if you test at room temperature. Your wind turbine blade is spending most of its operating lifetime at room temperature or below. It’s, it’s rarely, you know, above 30 degrees in Denmark and most of Northern Europe and, you know, also a lot of, um, a lot of America, not, not all of it But, um, in Australia it has just extended periods above that temperature and even exceeding the temperature where, you know, wind turbines have an operating limit and after that they will shut down.
But the operating limits are based on ambient temperature. It’s not based on what’s the temperature in the laminate, which is what really matters for blade lifetime. So anyway, I’ve been obsessed, like honestly obsessed about this issue for 10 years. Talked about it with anybody who would listen . But then when I started working in O&M in [00:14:00] Australia and I started seeing some wind farms with an abnormal number of cracks early…
again, early in their lifetime, you know, I think one of the wind farms I was looking at was maybe three years old or four at the time. I think it was three actually, and had a lot of cracks, and I looked at a few years in a row and it was more and more cracks every year and I’m like, “Oof, this really looks like end of life fatigue behavior.”
A- actually it’s not, y- you know, there’s this concept of a bathtub curve where, um, when you’re looking at failures in components, in, in anything, not just in, um, wind turbine blades, but you know, like you’d start– it’s called a bathtub because, you know, when it starts operating, you’ll get quite a lot of failures.
Anything big, any manufacturing defects or anything are gonna cause failures quite fast, and that kind of drops off over time as all of those, uh, get addressed. And then you have, you know, the bulk of your operating life, it’s like pretty low level, pretty, pretty constant for a long time and then as you get towards the end of the [00:15:00] life, you start to see failure rates rise up again.
That’s your fatigue failures, your end of life fatigue failures. And so when I saw the same types of cracks more and more each year, I’m like, “This looks like, you know, the foot end of the bathtub, not the head end.” And, uh, it made me worried and I’ve now seen that across a few wind farms in Australia at, um, hotter places.
There’s a few blade types that are more prone to it than others, but at this point it’s still a suspicion that that’s what’s going on. I mean, a suspicion backed by a lot of, a lot of theory and knowledge of how the certification process works. But this project now we’ve got some funding to actually go put some sensors onto wind turbines, actually learn what the temperatures are in the blades throughout the whole laminate, um, not just the, you know, on the outside surface or not just the ambient temperature, but actually, you know, develop a temperature gradient across the whole, um, the whole laminate in the blade shell.
Um, and [00:16:00] then we’re going to be doing a bunch of modeling basically to look at what is the effect of these different temperatures that blades are really seeing and how much would we expect to… that to decrease a lifetime. And then we should also be able to say, you know, if you have this issue in your wind farm, you might be able to change your operation a little bit and extend your lifetime a lot.
Because this one, it’s real– like, in contrast to leading edge erosion, leading edge erosion is just, it’s, you know, every wind turbine has it to a certain extent, and it, it’s always there, but it’s a relatively minor cost to fix it. You know, like it sounds like a lot, like 30, $40,000 per wind turbine, but, um, you know, compared to if you’ve got to replace every blade across your fleet because they’re all, you know, at the end of their life after five years, you know, that’s obviously shocking.
And, you know, that’s a bad example, but even in a y- you know, like a less extreme example, maybe [00:17:00] after 15 years you have to do a, you know, a f- a fleet-wide campaign to strengthen blades or something. It’s, you know, m- many millions of dollars for that, and so it c- could make sense to be able to learn, okay, what, what hours of operation should we be avoiding?
Additionally, because when it’s super-duper hot in Australia, usually you’ve got heaps of solar power and the electricity price is not that high. So I, I think that there– and I don’t, obviously, before we’ve done the project, I don’t know what the threshold is. But in both cases, we will be aiming to improve the knowledge of how you can operate to avoid these periods of accelerated damage.
Allen Hall 2025: Do you think you’re seeing more fatigue-like damage due to the blades operating when it’s hot or not operating when it’s hot, with maybe less airflow around the blade and maybe less cooling going on is just a temperature soak At rest? [00:18:00]
Rosemary Barnes: Yeah. It’s interesting because the temperature is higher if it’s not rotating, um, because you get a whole lot of, um, convective heat, heat transfer when the turbine is operating.
So your temperatures are not gonna get as hot when operating as when they’re standing still. However, if it’s standing still, they’re only very lightly loaded. Like, yes, they’re gonna get, um, blown by, by gusts and, um, have a little bit of bending, but it’s, it’s very, very small compared to, uh, if it is y- you know, operational loads.
Uh, assuming that you’re not in the middle of a s- a storm. But yeah, a storm probably doesn’t come with 50 degrees temperatures.
Allen Hall 2025: And what part of the blade is susceptible to these higher temperatures? Is it the resin? Is it the fiberglass or carbon fiber? Or is it the, the glue, the bond joints? What part are you focused on?
Rosemary Barnes: The resin is the main part that I’m focused on. It gl- it could be an issue for glue too, actually. I haven’t even looked into what the, um, yeah, temperature assumptions are with, with glue, with [00:19:00] bond lines. But the failures that I’m seeing in the field are not, are not bond line issues. It’s, it’s, um, a laminate problem.
Allen Hall 2025: What about balsa and foam inside of the blade? Are they affected by the temperatures or are they pretty temperature stable?
Rosemary Barnes: I don’t think they’re affected at these kinds of temperatures, no. They, they don’t really do much actually. The, the core materials, like it, it is very important that they’re, that they’re there, but their job is really to keep the fiberglass separated from its- itself to make it stiffer.
So, um, yeah, that’s, that’s unlikely to be a, a major source of problems.
Allen Hall 2025: So this study is gonna work over about three years, and you have a number of wind farms that are participating. Are you looking for more wind farms to participate in Australia?
Rosemary Barnes: Yeah. Yeah, definitely. I mean, we can, um, have as many as, as people want to join.
We’ve got quite a good selection so far. Definitely can always welcome more. A, a bit limited in how many can get the really, um, good sensor [00:20:00]package, because the grant funding is a, you know, a certain amount, and that’s paying the bulk of those sensors. So, um, those spots are limited. So if anybody wants to really zone in on what is specifically causing erosion on their site, you know, if you know that you have got leading edge protection that is not good enough and you have to replace it soon, but you don’t know what to replace it with, then, you know, that would be the kind of wind farm that might want to consider, yeah, joining this and, um, you know, getting these sensors on their, um…
We’re putting them on top of the nacelles, most of them. Um, yeah, so that would be a good match then. Um, and then, yeah, for the ones that are doing the SCADA data and, um, weather data- There’s not such a, a hard limit on how many we can have join like that. So yeah, we can have more, more like that.
Allen Hall 2025: In the temperature fatigue effort, i- is that still looking for participants or are there particular wind turbine types or manufacturers that you’re [00:21:00] looking for to participate?
Rosemary Barnes: Yeah, I think, um, I, I mean yes, we can have more of those. That’s a simpler, a, a simpler issue as well. The sensors are not so expensive and, um, it’s, yeah, it’s a, it’s a simpler project to join that one. We only need, you know, a couple of turbines per site, so it won’t be such a, uh, an involved process to get everything up on into the turbines.
And in terms of who might like to join that, I would say anybody that is in a really hot area where, you know, where they see a lot of days over 30 degrees, and if they see any days, you know, getting into the high 40s, then I would say that that’s worthwhile. Or even I have seen this issue in some milder sites, um, yeah, depending on the, on the blade type as well.
It is more common with polyester resins. They have a, a lower op- uh, maximum operating temperature than epoxy resins. But then also just anybody that has noticed just, hey, [00:22:00] we’ve got a lot of cracks, and it seems like we’re getting more and more cracks every year, which to be honest, can be hard to keep track of if you’re…
If you’ve got a full service agreement, uh, you know, an OEM managing your wind farm The early signs of this are gonna be category one and category two cracks. They’re not in exactly the same location. It’s, you know, it’s a tricky one. Normally, if you’re looking at a serial issue, then you’re going to have, uh, well, you know, your ideal pattern for a serial issue is the exact same thing happening over and over again.
And so it is harder to pull this out. It also really would be very rare for it to be happening in the first two years or three years, whatever your serial defect liability period is. So it’s quite hard. But, um, another group of wind farms that might like to consider it is if you know that in, you know, a certain number of years you have to renegotiate your service agreement or, you know, it ends and you might have to take over yourself, then this’ll be a really good way for you to [00:23:00] understand, you know, have I got a ticking time bomb here?
Um, because it’s not something that you’re gonna be aware of if you haven’t been, you know, doing some really, really in-depth shadow, shadow monitoring of your blades, you know, running your own inspections and looking at every single damage, not just category three, four, five, but lower ones. So yeah, I mean, there’s a, a wide variety of people that, that could be interested in joining.
Allen Hall 2025: Are you expecting a number of manufacturers that make leading-edge protection or involved in resin creation, some– there’s a number of resin companies and a variety of resins that are used globally, sort of interchangeably at times. Are you expecting some of those companies to participate in this effort just to learn about the Australian environment?
Rosemary Barnes: I think it would be a good opportunity to test out some products and see how they behave in the Australian context. I think that that would be a really good selling point, but I, I have to say that most of the companies doing that sort of thing that wanna enter Australia, they don’t [00:24:00] really consider…
Like, from the perspective of wind farm owners in Australia, if you can’t show us wind farms in Australia where this has worked and, you know, show us a before or after, you know, the old LEP lasted Two years and our LEP is going on four years now with no damage. It, you know, unless you’ve got a before and after like that, you can tell us however many turbines that you’ve got installed around the world, but, um, we don’t consider it validated, y- you know?
It’s not validated for Australian conditions yet. And I do have this same discussion over and over again with, you know, not just leading edge protection, but all kinds of, um, you know, manufacturers of whatever doodads that you put on to improve a, a wind turbine. It’s so different to Australia. Things break so fast.
And I’m talking everything, you know, like vortex generators fall off and, um, yeah, like, uh, you know, bits of lightning protection systems fall off, seals just [00:25:00] crumble and disintegrate. Um, and it, you know, we’re very wary of, of new products. So I, I do– I mean, I’m thinking of it more from my client’s point of view than from the product manufacturer’s point of view.
But one thing that I wanna get out of this pro- project is to be able to answer one of the most common questions that I get is, which is, what leading edge protection should I be putting on my turbine? And for now, I don’t know. I, I know a range of products that don’t work in Australia, and not much more than that.
So, um, yeah. And it’s also, you know, Australia’s a very varied place with lots of different kinds of climate too. So it’s not gonna be like, you know, the product that works in Queensland is the same one that’s gonna work in Tasmania, which is the same one that’s gonna work in Western Australia. You know, um, so it, this project is gonna really pull out what are the site specific issues you’ve got at your site and what kinds of, um, you know, tests would we need to see a product um, perform in order to know that this [00:26:00] is gonna last on your site.
Allen Hall 2025: W- what is the outcome of this project or these two projects? Are they gonna be reports or, uh, a, a continual monitoring system that’s designed for the Australian environment? How do you see this going?
Rosemary Barnes: Yeah, so one part of it is, um, developing a way to identify periods of accelerated damage and to know not to operate during that time.
So we call it protective operation. Uh, so that would, uh, help you if, yeah, you’re trying to extend the life of something or increase the amount of time before you have to repair, then y- you know, that would be useful to have that knowledge. And it will be as simple as just an alert saying, “Hey, accelerated damage conditions.
Consider, you know, if you wanna keep on operating.” And, you know, if the price of electricity is super high at that time, they may want to push through, and if it’s low, they probably won’t want to. So that’s one thing. Um, especially, you know, as wind turbines get to their, near the end of their life. I’ve got some clients whose wind farms only have, you know, [00:27:00] maybe five years operation left.
They just simply don’t wanna repair their leading edge protection again. They just, they, they don’t wanna do that. So they would be happy to, you know, reduce operation a bit and have their turbine limp through to the end of the period. Y- you know, you want everything to wear out at once. You don’t want brand-new leading edge protection on a turbine that’s going to come down in a couple of years.
Um, so, you know, that’s, that’s one part of it. And then the other thing is, you know, turbines earlier in their lifetime, how can we optimize the maintenance schedule with leading edge erosion? Um, so, you know, like it’s a lot cheaper to, uh, replace the LEP if you get– catch it early, but then you don’t wanna be catching it too early and replacing it, you know, constantly when you, you don’t need to.
So, um, yeah, it, this, having this knowledge will enable a site-by-site operations and maintenance strategy with respect to leading edge protection. We also have some sites who are having trouble. They’ve got a full service agreement, and the OEM is [00:28:00] responsible for, um, doing the leading edge erosion repairs and protection replacement, but the owner is on the hook for paying for it.
At the other end, we’ve got people with full service agreements where technically the, um, manufacturer is supposed to be doing the leading edge protection and paying for it, but they argue about what, when does it need to be done. Because, you know, um, the operator might think if there’s no structural risk, then we don’t need to be replacing it.
And in the meantime, you’ve got turbines spinning around for years and years and years with, you know, these huge flakes of leading edge protection s- you know, causing the flow at the tip of the turbine to, to detach and to stall, and horrible aerodynamics, huge losses in power generation and revenue. And they’re having a big fight about, you know, is this necessary to do or not?
And then, you know, they’re just gonna put the exact same product on again ’cause the [00:29:00] OEMs are re- all really, really wedded to their own particular brand. It’s like, “Well, last time we had this product and it was factory applied, it lasted one year before it s- it was worse than, you know, if it wasn’t there at all.
Uh, we don’t really want you to put that one on again.” And so, you know, having the information that they need to be able to, you know, really bring data to these discussions and, you know, makes a, yeah, data not drama. That’s a, a good approach I think, um, for any kind of negotiation and especially in the case of leading edge erosion.
And then for the high temperature fatigue part of the problem, aside from, you know, just wanting to know are your blades aging, should you be looking at remediation action or changing the operation, the other really big key thing is, uh, you might need to have a fight with y- your OEM about if this turbine has been designed and operated correctly.
And so then having the data from this, um, project is going to give you the information that you need to come into that [00:30:00] argument with, again, the data not the drama. Um, and to, you know, in- increase your chances of succeeding in that kind of really tricky negotiation.
Allen Hall 2025: So if you’re an OEM or a manufacturer of equipment, an ISP, an operator, pretty much all aspects of wind operations, you probably ought to be getting a hold of Pardalote Consulting and Rosemary to talk about the opportunity to participate in this study.
How do people get ahold of you to, to do that?
Rosemary Barnes: People can go to our website, pardaloteconsulting.com, and get in touch via the contact form there, or you can, uh, look me up on LinkedIn, Rosemary Barnes. That’s probably the easiest, fastest way to get ahold of me personally.
Allen Hall 2025: Well, Rosemary, congratulations on the Energy Innovation Fund Awards and the new three-year effort.
If you are interested in participating with Pardalote Consulting and working with Rosemary and her team [00:31:00] in Australia, reach out to her on LinkedIn and get that process started, because this report and the data from all this analysis that’ll happen over the next couple of years will be important to the wind industry.
So you need to spend some time and get ahold of Rosemary and get this process started now. So Rosemary, congratulations. Uh, thanks for being back on the podcast, and looking forward to, uh, the next couple of years. It sh- should be exciting.
Rosemary Barnes: Thanks so much, Allen.
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