Weather Guard Lightning Tech

Aerones Robots Scale LEP Repairs Across the US
Dainis Kruze and Janis Putrams, co-founders of Aerones, welcome Allen to their new Denton, Texas facility to discuss robotic spray-coat LEP repairs, third-generation internal blade crawlers, and their US-made inspection drone that eliminates Chinese components.
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Allen Hall: Dainis and Janis, welcome back to the program.
Dainis Kruze: Thank you, Alan, for visiting us, uh, in, in our new facility.
Allen Hall: Yeah. Is a great new facility. We’re in Denton, Texas, which is just north of Dallas. Uh, and you move from. Lake Dallas area. Mm-hmm. And we had visited that facility a year or so ago. This new facility is amazing.
It’s what, probably four times the size. Yeah. Maybe a little bit bigger. And it is, uh, indicative of the growing business that Aeros has in the United States. And that’s wonderful. Uh, and I’m glad I could catch you in Texas ’cause I know you, you guys are running around the world all the time. Uh, I think the last time I was at.
A facility with both of you was over in Riga?
Dainis Kruze: Yes.
Allen Hall: Uh, probably two years ago now. Oh,
Dainis Kruze: yeah.
Allen Hall: So I saw the Riga operation and, and now we’re seeing [00:01:00]the, the Denton US operation. You have facilities in other places too, right?
Dainis Kruze: A small one in Australia, but, but yeah, the main facilities in Riga and the second biggest one here in, in Dallas.
Allen Hall: A lot of technology changes since Rose Riga. Uh. Leading edge being the big one, leading edge protection materials. And when I talk to US operators, even operators in Australia, we’re just there. They love the idea and the application of a robot for leading edge repairs.
Dainis Kruze: Oh yeah,
Allen Hall: it makes total sense. It’s one of those areas that, uh, Rons has shown you can do this with a robot much more consistently.
Has that business grown quite a bit since you first started it?
Dainis Kruze: Oh yeah. Oh yeah. We did more than 500 turbines last year, so we. The plan for this season is about one and a half thousand turbines, so it is growing quite a lot.
Allen Hall: So the, the speed and the quantity of robots here in the United States is must have grown considerably.
Dainis Kruze: Oh, yeah. Uh, one team now gets [00:02:00] up to 15 turbines a month. So if it’s category one or two turbine, uh, leading edge, uh, erosion, it’s about one day to do one turbine category three. Uh, one turbine is being done in two days, and we are talking about like 12 meter repair. It’s not a spot repair, it’s a full repair, like
Allen Hall: full repair.
Okay.
Dainis Kruze: Yeah.
Allen Hall: And the robot technology and the, the amount of technology on the robot is behind us has grown quite a bit. Uh oh. Yeah. You’re learning as you’re going. Obviously. I looked at a number of robots in at the Denton facility. Smarter robots. More data, more consistency. Particularly because the leading edge protection materials require a lot more care than rope technicians can generally create on site.
Right. Walk us through what this robot is doing, why it’s doing what it’s doing, and, and like the, the quality you get coming out of it. ’cause what I see behind me is really nice. Better than, than [00:03:00] what I’ve seen typically coming out of a factory.
Janis Putrams: Yeah. So multiple things actually we’ve been. Kind of what we’ve been hearing sometimes is that, um, that material’s good, the application seems good, but then it comes off after some time and you don’t understand what’s what happened, right?
Yeah. So we understood to, to make it right. We need to make sure that both the kind of, we take the full ownership for the, for the whole process, for the application. And so we’ve been investing quite a lot in our lab to, to actually understand what the material needs, how the surface needs to be, be prepared.
How do we measure it? How do we make sure the process is right? So actually what we saw is that, yeah, making sure adhesion, uh, is, is right, is is very important part. Also, when you go out there, there’s a quite a spectrum of the weather forecast, like information. You have humidity, you have temperatures, and you need to be able to guarantee the, the, yeah, the output in all of that spectrum.
So yeah, we’ve done quite a lot on, [00:04:00] uh, on those. And
Allen Hall: so from a technology perspective, you’re incorporating all those measurements actually into the robot. So you know what the temperature was when the application was made, you know what the humidity was, you know what the mixture was exactly. Remember the temperature of the, the ingredients that went into make the, the LEP material.
That’s remarkable. And now it’s, uh, I think a lot of people think of LEP as being something you would apply with a, you see it still, you see it with rollers and sort of. Basic human tools. You’re spray coating today. Yes.
Janis Putrams: Yes.
Allen Hall: And the, the smoothness of that coating is remarkable.
Janis Putrams: Yeah. For example, I dunno if you, if you know in factories where the cars are made Yeah.
You don’t see people rolling the car. Yeah. So, because the, the spraying technology, it enables us to actually guarantee the robot when it moves, it moves in a constant speed. It’s not manually, it’s kind of on a cruise control. So it’s, it’s moving in a constant speed [00:05:00] and the spraying is constant. And so yeah, the, the thickness is, is, is always the same.
And also it kind of nicely tempers off on the, on the sides. So there’s no vortexes, kind of, no aerodynamics loss. Uh, so yeah, it, it comes out very, very nice and
well.
Allen Hall: That’s the thing about when you put a leading edge coating on, a lot of times there’s a taped edge or a hard edge there. And then they gotta come back and try to fill it.
Or maybe they don’t fill it and the filler doesn’t stay. It may. I’ve seen all varieties of that. So when you spray coat it, not only do you get a very smooth finish, aerodynamically, you lose the step on the backside. Right. So the, the entire assembly is, is just more aerodynamic. And that’s the reason you’re doing in the first place.
Mm-hmm. It’s not just we’re recovering this shape. Yes, you’re recovering the shape, but you’d like to get some more power outta your, your turbines. That makes sense to me. When you’re, uh, cleaning the blade too. There’s a lot of technology about just getting the blade prepped because we’ve seen so many times where a leading edge coating’s been applied to a very [00:06:00] poorly prepped blade surface, and it just doesn’t stick.
A year later, you’re out doing it again. Describe what you’re doing on the prep side.
Janis Putrams: Yeah, so what we also see, uh, saw that, um, if there’s some damaged material, it’s very important to get it off. If you put it on top of the damaged material, it’s just not gonna hold. So we have one of those robots, it has quite a powerful kind of belt sanding tool, uh, where you can truly take it off.
And then the second tool prepares the surface and also the tool kind of makes sure that it’s not up to the, to the operator to choose which point to, to prepare, but just the tool goes in, in a single step and prepares all of it so we can kind of. Be sure that nothing’s missed. And then when you, when you put it on, uh, then, then what’s gonna, it’s gonna hold.
Dainis Kruze: And to develop that tool. We have a laboratory where two chemical engineers are actually working and testing and doing pulley tests and surface, uh, adhesion tests [00:07:00] and, uh, to get the result, the best result possible. Because, as Ian said, we’re taking, we, we are giving guarantee, uh, of our work. Uh, and we don’t do that.
Oh yeah, it peeled off because the material was bad. We, we, we take the guarantee of application and materials that it’s gonna be stick, uh, is gonna stick and it’s gonna stay there.
Allen Hall: I think there’s a lot into that. And having been to the Riga facility, I understand you have a lot of capabilities there.
When we talk to. Independent service providers and they’re applying materials. They’re not doing all the research. Oh, yeah. That aone is doing. You, you are actually looking at material properties, you’re looking at surface conditions, you’re looking at the chemical reactions that are happening. You’re doing the mechanical pull test.
You’re putting engineering behind it. Oh, yeah. Which, which has to happen. We’re still early in this leading edge protection world. We have, we don’t have 50 years of experience. We have two or three really good years, and we’re still learning and there’s a lot of different materials being proposed right now.
That mechanical testing and evaluation [00:08:00] laboratory really raises the bar.
Dainis Kruze: Oh
Allen Hall: yeah. I think in terms of just what you’re expecting to get out and, and EC saying, you back up what you do. Oh yeah. Which is completely different than the rest of the industry. De describe what that means to an operator that chooses their owns to do leading edge protection.
Dainis Kruze: Yeah, it’s a turnkey, uh, solution, right? So, uh, you won’t get in a situation when, um, somebody comes, supplies the material and after a year it peels off and then you, um, have months and months of debating and negotiating, right? Uh, whom to blame, right? So who will take care of that? Um, and in the end, basically, you don’t know either that was a material or that was a applicator.
Um, that’s it, but. The result is not met. Right. So the the, yeah, the the still, the, the blade is not protected. In our case, we take full responsibility, full accountability. If the material is gonna put peel, uh, peel off, we are gonna come and fix it.
Allen Hall: Because I think a EP loss from leading edge erosion is one thing.[00:09:00]
A EP loss from a bad leading edge protection material that’s peeling off is exponentially worse from what I have seen. It just gets very draggy. Yes. And that material just starts to. Actually create massive drag. So you need to get that bad material off. And I think a lot of operators that have used other services probably won’t be calling you this year to go, we need to sand that off and put on something with robot.
Dainis Kruze: Oh yeah.
Allen Hall: Does that then change the dynamic because of the, the amount of robotics, uh, applications you can do in a year where before when we talked to operators, us Europe, robots are nice. But we don’t see the ROI.
Dainis Kruze: Mm-hmm.
Allen Hall: Has that flipped on its head now where the robots are just so much faster than rope technicians, that it just makes sense to do it with robots?
Dainis Kruze: I still, we even have systems in our portal where customers can see, um, at which category, how much of efficiency they’re losing, uh, during the year. Yeah. So what is the a a p loss and roughly speaking, it’s like three, four years of return of investment just [00:10:00] on AP loss. If you’re not fixing it at category three, you’re gonna lose in two, three years.
Same amount of money as on investing on, on repairing that. Yeah. So the return of investment is two, three years, uh, worst cases for four years. Um, as we see, um, and not even speaking about, uh, when the erosion happens to, to category four and five, your repair cost is just like at least double or triple. So you don’t want to do that in category fours and fives.
It’s lot smarter to do that at category two, three.
Allen Hall: Oh, that makes a lot of sense. However, I would say that a lot of operators worldwide let it get to three plus. Mm-hmm. Before they start to worry about it. Alright, so the, then the question becomes, am I gonna put a bunch of technicians up on ropes anyway to go fix this?
Or is there a robotic solution that I can fix those leading edge, uh, where the, the, the glue has been eaten away by leading a rosn. Can I fix that without putting technicians on ropes?
Janis Putrams: Right. So currently we are [00:11:00] doing categories like 1, 2, 3.
Allen Hall: Yeah.
Janis Putrams: Um, if we have category four repair, we would cooperate with a rope technicians.
They come and laminate, and then the robot does, does everything else. But there’s a, yeah, there’s a new, uh, new technology that we are working on, which is kind of a reinforced, uh, yeah. Application on the leading edge, uh, where we can be able to actually repair category for. Uh, for as well.
Intro: Mm-hmm.
Janis Putrams: Yeah. This, and it’s, um, it’s a uv uh, UV curable solution, uh, which is also great because you can apply it in, in, in, in, in humid environments, in, in colder environments.
Um, and then, and then of course the, the, yeah, the, the leading kind of protection that we put on would go, go on there as well. And, and this is actually quite a, um, amazing, uh, uh, yeah, sample. So for those who don’t know this, this goes into rain erosion, uh, kind of machine test machine. And [00:12:00] uh, and then they get kind of the spin and, and, and rain droplets are, are falling.
And, and, and then you measure how long it lasts. And, and this has been in there for 200 hours and we actually had to stop the test because it was becoming just outrageously expensive. But it’s, it’s like a lifetime, like the, the turbine would not experience this amount of erosion in lifetime, so we thought it was
Dainis Kruze: 130 meters, uh, per second.
Uh, speed. Speed. Um, but, and yeah, as Ian said, like we also have a system in our portal where you can look up your, any wind park in us, and it’ll tell how many hours per year you have this severe, uh, rain, which would be like compatible with, uh. Close to this, uh, speed tip speed and, and the rain. And basically there is no wind park in the world, uh, where the erosion would happen, uh, where the rain would be like 200 hours, like, uh, in, in, in lifetime of the turbine in 25 years.
Hmm. So basically [00:13:00] it’s in most of the cases it’s like four or 5, 6, 7 hours a year, which means like basically it’s gonna last for 30 years, um, like in, in a, on the rain erosion test,
Allen Hall: but really only if the application is good.
Dainis Kruze: Only if the application is good. Yeah.
Allen Hall: That which is the key, right? Yeah. So you can have the best material in the world, you can have the best lab results in the world, but if you can’t repeat it out of the world Yeah.
Then it’s just a waste of time.
Dainis Kruze: Yeah.
Janis Putrams: Yeah,
Dainis Kruze: exactly.
Janis Putrams: There’s another interesting aspect that we, we saw when we, because we, we did a lot of those tests and what we noticed is that the surface smooth smoothness, uh, actually is also very important because like if it’s more like an orange peel, you get those cavities and when the rain droplets hit.
They kind of, they, they creates more like a stress concentrations there just
Allen Hall: a
Janis Putrams: pull. We’ve seen like, like about the performance kind of getting into half. If the, if the surface is not, not, not smooth.
Allen Hall: And that’s what you see in the field when they apply it by hand. It’s not nearly as smooth as what I see on the spray version here with the robot.
Janis Putrams: Mm-hmm. And [00:14:00] once it finds a place where the erosion can start, then it just grows.
Allen Hall: That’s the magic. Right. I, I know a lot of operators don’t think about all those little details. Mm-hmm. But because roads has the ability to do the work, to do the manual motion testing, to do the lab testing, to look at the materials and apply it.
Like it should be that that’s a game changer.
Dainis Kruze: Yeah. And, and scale it. Right. So when we do this with robots, like, uh, like most of the job is done by the semi-autonomous robot. So it’s not again, um, a bottleneck of how many good technicians you have,
Allen Hall: right?
Dainis Kruze: Like it’s, it’s, uh, it’s about technology which is doing the job.
And you will have a consistent result, whether it’s Australia, US, or Europe, you will have exactly the same result, uh, because it was done by exactly the same robot.
Allen Hall: Well, speaking of robots, uh, the latest gen three internal crawler is remarkable. Uh, Yana should give me the details of all the cool features that are on it.
I’ve seen it in video. I haven’t seen it out in the world live [00:15:00] inside of a blade yet, but I will this year. I think there’s a lot of technology in there from your first gen robot to, uh, this third gen. The pictures that I’ve seen downstream are really good. Because it matters and, and because there’s lot of the defects you can’t see on the outside.
You need to be on the inside.
Janis Putrams: Mm-hmm.
Allen Hall: Uh, core, uh, bonding, most of them. Well, that’s true then. That’s totally true. No, the industry, you’re right. I do, I do think we started off on the outside because that’s what we could do. Mm-hmm. Not realizing that probably we should be on the inside should sort of started there first.
But the robot now is so much better at taking pictures. And if you, if you can take pictures, but the pictures are not so good, why are you wasting your time even taking them?
Janis Putrams: Right.
Allen Hall: Explain what’s all in that robot to take high quality images and to focus on the defects that you find.
Janis Putrams: Right. So kind of, we’ve done a lot of inspections with our previous generation crawler and, and then we, we got a lot of feedback also, and we, we do [00:16:00] ourselves the, the inspections of the, the data, uh, and give, give information to customers.
So we worked our way back. And also not just that, uh, when you go out and do it on a big scale. You get feedback, like, for example, from the technicians, uh, what’s easy for them, like different blade models, maybe some specific blade models have some obstruction in there that you need to drive around. So, so those kind of small details when, when you gather and, and, and, and even just manufacturability to make sure that, uh, yeah, it’s easy and faster to manufacture, easy to maintain.
Um, so, but that’s, yeah, that’s, that’s the kind of, uh, the part on. On the, on the inspection itself, uh, of course it has a improved 360, uh, kind of inspection. So we gather everything. Uh, there’s additional camera for, uh, much detailed kind of areas. For example, the, the root zone, you would want to, to have the kind of the top part inspected [00:17:00] in higher resolution, but also it has like a smart feature where you can tell that, for example, particular area in the blade, if you want that in a higher resolution.
So when it gets there, it, it would point and, and, and take that particular area because maybe there’s a serial defect and you would want it in a much, much higher, uh, higher resolution. Also, what we got feedback from, from customers is that for them, it’s very important that, for example, if there’s a defect, you want to know exactly the size of the defect, and you want to know exactly the distance to the root.
And maybe you want to, you might need to open the blade from the outside and you don’t want to be off by even a half meter. So we’ve been working a lot to, to improve that. But it’s like centimeter precision
Allen Hall: because a lot of the defects are actually happening closer to the root. I, I think lightning company, which is what we are, we get a lot of defects kind of further towards the tip, but the manufacturing defects that really matter are closer to the root [00:18:00] and they tend to, if you think about the root that’s.
The largest diameter part of the blade. So you need to be able to take really good images where the rover is not right next to the damage that matters. Mm-hmm. So you’re looking for megapixels, you’re looking for light intensity, you’re looking for exposures right to be right so that you can actually measure it, track it.
So even if you notice there’s a crack talking to operators, there’s a crack. Okay. But is it propagating yes or no? If you can’t measure it, actually, you can’t tell if it’s growing or not, which is ultimately. What you need. So those improvements are gonna be a, a massive improvement in terms of the operators buying in because we talk to operators all the time, you need to be doing internal inspections.
And they say, yeah, sure. Like, no, no, no, no. You don’t understand. You need to do a set up internal inspections so you understand what’s going on inside your blades because there are a lot of like kind of serial defect things or uniqueness things that happening, or wind, wind specific events that are happening and are causing issues with your [00:19:00] blade.
And that gets me to outside the blade. So, uh, once you’ve done the internal inspections and you should be doing some external inspections, particularly for lightning and some other issues. Question in America right now is you can’t use a drone that has Chinese components in it. There owns drone image.
Those are all Chinese free, ready to go right now to take high resolution images. And there’s actually more technology. Yeah. And this drone that I’ve seen in, in previous versions.
Dainis Kruze: Oh yeah.
Allen Hall: Tell me about that.
Dainis Kruze: Yeah, it’s us made, uh, so we, uh, are, are compliant, um, with, with the rule, uh, regulations that you can’t use the Chinese, uh, parts.
That’s one thing. Another thing is like how the technology works. So, um, we have very sophisticated system how the drone flies and scans the blade, uh, the blades and the turbine itself. So we don’t need to put the blades in particular angles like you. [00:20:00] Whatever the blades are being stopped, the drone is gonna be capable of doing that inspection.
Um, that saves time, uh, time and makes it easier. Also, you don’t need to navigate, like if you take the drone and do the inspections yourself, you just push start and the drone does, uh, all the jobs. So you don’t need to fly to point it at the tip of the blade or whatever it’s gonna do. 100% of the jobs is gonna be by, by, by itself.
Um, and also like we have, um, a. Bigger angle, like variety, how we can put the camera. So we always will take the picture from the best angle. It’s not gonna be, look, you’re not gonna look at the crack under an angle. You will look at the, uh, crack directly, uh, onto it and it actually, it actually moves the needle.
It, it, it’s very, very important when you’re reviewing the data.
Janis Putrams: Yeah. So basically what you want to do is like, if you want to take a picture of this. You want to be looking perpendicular to it.
Dainis Kruze: Mm-hmm.
Janis Putrams: And, and if the turbine is like this, you, you want like, you want want to look like this and if the blade kind of, you go from the top, you [00:21:00] want to look like this.
So this drone was built, it wasn’t adapted, it was built particularly for wind turbine inspection. So the kind of, it was taken account that it can do all these angles Exactly as, as they need for, for, for blades. So to, to get the, the, the best, uh, inspection data.
Allen Hall: I’m always surprised at the lack of quality of inspection images for cracks.
I see a lot of them because we get sent a lot of lightning damage mm-hmm. Inspections to go through and, but we see the cracks. Also, when I look at the crack, it’s always at an angle and I think, how do those engineers even have a sense of what the scale of that is? Because I can barely see it in this really poor drone image.
Having something that’s actually 90 degrees to the damage is. A game changer because now again, going back to there’s a crack, but what do I do about it? If it’s not growing, I may just live with it. Mm-hmm. But you can’t measure it if you don’t have a good, consistent image of it, which everyone’s thinks about.
Right.
Dainis Kruze: Not only image, but also a 3D model of the blade. So because we are scanning [00:22:00] it with the lighters, we actually have a 3D model of that blade. So we can actually physically measure, we understand what we are seeing, uh, and we can measure, uh, with high precision. So both the internal crawlers and the drones are by far the best, uh, robotic technology for wind turbine inspections, uh, in the industry by far.
Like, uh, yeah. Uh, nothing comparable in the, in, in the industry.
Janis Putrams: Yeah. What Dyna says, it’s that the precision is also important for another aspect, because when you have a drone inspection from the outside, an internal inspection on the inside, and you have this precision, what you get is that, for example, there’s something on the inside of Blade.
And you want to see what’s on the outside. You can flip in, in our portal, you can just flip and look at it from the outside and you say, oh yeah, there’s something on the outside and what’s on the inside. It gives you much better understanding what the defect to release. Is it just on the inside or is it already propagating on the outside?
Dainis Kruze: Yeah, and it’s one click. It’s not reviewing two reports, uh, trying to understand, uh, going back [00:23:00] and forth. It’s just one click you and you get outside.
Allen Hall: Well, let’s talk about the software platform. There is a software platform. It is called the
Dainis Kruze: your Owns platform. Okay.
Allen Hall: You guys gotta
Dainis Kruze: work
Allen Hall: on a name?
Dainis Kruze: Yeah, we, we haven’t blocked on, on the name.
Yeah, we should. We should.
Allen Hall: But the, the Eros platform is a useful platform because you can have all the images you want, but they’re not really useful unless you can correlate it back to what the blade design is and then figure out where. The the crack or the DA or whatever this is going on. Where it is on the blade.
Exactly. So then you can assess whether you need to have a response to it. Do you need to derate the turbine, shut down the turbine, or just let her run? Those are big, important decisions to make because it has to do with profits at the end of the day. That platform allows every the engineers to do that.
You’re seeing more adoption of that platform by the Oh yeah, by the operators.
Dainis Kruze: We are stepping up. Me and Jans, we actually graduated, uh, computer science. So we are software developers by [00:24:00] education, not the mechanical engineers. Uh, uh, and we, we, for, for all of these years, we, we’ve worked more on the robotic technology, how to get the data, how to get the best quality picture, how to, uh, get the, uh, best quality data.
Um, and now we have stepped up on the portal development and, uh, again, uh, in, in, we’ve built the best portal in the industry, like seamless review of the data of internals and externals and lightning protection system tests. Um, and, uh, yeah, the easiness, how to you, you can use the, the system, uh, review the data, uh, navigate, see the.
Um, different kind of analytics and, and help from our blade engineers on decision making, um, is again, the best in the industry now.
Allen Hall: Well, you mentioned lightning protection resistance measurements because it’s something you’ve done for a number of years now, and I run into a lot of operators that say we’ve, we’ve had our drones do the LPS resistance measurements.
They should still be doing those. I think there’s, because Aeros has done it [00:25:00] so well and has a, a nice data set with it. Operators are thinking, I don’t I need to do it anymore.
Dainis Kruze: Yeah. It’s a, uh, it’s
Allen Hall: a conflict, isn’t it? It, it, it’s, you get so good at one thing that, that it changes the dynamic of the industry.
Dainis Kruze: Oh, yeah. I, I think, I think that we are a bit, we, we need a bit more data on understanding, um, how much these lightning damages actually cost. Yep. Comparing to what would cost, uh, like a proper inspection campaign.
Allen Hall: Yeah.
Dainis Kruze: So kind of in a, in a way, you know, like these lighting damages are not there yet.
Allen Hall: Yeah.
Dainis Kruze: Why should I test anything? Yeah. And when you get that lighting damage and you lose a blade and it have a fire it to fire. Yeah. Or have a fire and you have, uh, hundreds of thousands, if not millions in losses, it’s already too late. It is. Yeah. It’s, uh, and, and that’s, and that’s an issue of the. Chicken and egg.
Uh, yeah, I think in the industry. Uh, but, but I see that the industry [00:26:00]is improving and we do more and more of these lighting protection system tests. Um, customers are becoming smarter on this and, and, uh, I hope, uh, that it’s, it’s, yeah, it’s gonna, and it’s gonna get to the right place.
Janis Putrams: Also, what we saw is that sometimes we, we would give reports to the customer that, for example, for this Blade lightning protection is not working.
So they are asking like, okay, what’s next? Yeah, what do I do with this data? Right, right. So we developed a kind of a tool which helps to actually track exactly where that damage is, where that cable is, is kind of connection is lost. Uh, so it’s kind of like a, I dunno, same as you would kind of, uh, look for, I dunno, golden coins or something.
So it’s kind of a similar technology. The robot goes up and it kind of, uh, slides, kind of scans, uh, very closely to the blade. And when you find the, where the cable problem is, it has actually like a red marker and it can make a mark on the blade. Uh, so [00:27:00] actually if the rob guys, if they need to go up and, and open up the blade to fix the cable, they know exactly where, where to look.
So it’s not, again, you’re not doing it half a meter away or, or you can open up and then fix it.
Dainis Kruze: We call it open circuit finder. For, at least for that, we have the name.
Allen Hall: It’s a very useful thing though. I think the, the more that you get out to site, the more you realize what the problems are, what the priorities are, and design solutions around those. The linet protection one is obviously, is massive, right? Mm-hmm. You just kind of see it everywhere in, uh, particularly United States and Southern United States.
You see leading erosion being the, the number one. And then lightning damage being number two, when you see a lot of operators going after both of those things simultaneously to save money, that’s a massive improvement than five years ago. The, you guys have really changed the industry. There’s, everybody’s starting to think a little bit differently about how they approach the repair [00:28:00] season that, uh, owns, has extended the repair season.
So a lot wider window than it was. It’s not just March to October. Yeah, almost a full year at this point because of the technology the robot brings and the amount of data.
Dainis Kruze: Mm-hmm.
Allen Hall: Now everybody can react because they have something to base their decisions on. That’s, oh yeah. That’s impressive. It’s hard. I know you guys have a hard time seeing that because you’re in the day-to-day of Yeah.
Of trying to run a company has paced in, in Riga and you got places in Australia and America, so it’s a lot. But I do think deep breath, take a look back. You really have influenced the industry in the positive in a lot of ways. Thank you. Congratulations on that. It’s impressive. It really is. And uh, you know, when we talk next time in a year from now, probably you’ll have more done out in the field and you’ll have done several thousand turbines leading edge protection and you’ll have that history and you’ll have that data.
That’s [00:29:00] remarkable. Now your season. Your calendar is getting pretty full with a lot of operators calling you, saying, I need you out here to do leading edge protection and a variety of other tasks. Is there any room in your schedule right now to get on it and, and how do they, how do they get on your schedule?
Dainis Kruze: Oh yeah, there is room because we are building 30 additional, uh, leading edge repair robots. So it’s, it’s quite a lot. Like one robot is actually doing, um, up to 150 repairs a year. So it’s, it’s, it’s quite a big capacity. So yeah, we’re building more and more robots. Demand is there. Um, and, and the wind industry is gonna generate more clean energy because of that.
Right. So because bleeding edge erosion affects the efficiency and, and we are fixing that.
Allen Hall: Improving the profitability of all these operators.
Dainis Kruze: Oh yeah.
Allen Hall: Which is what we should be doing. So if you haven’t contacted our owns, just Google our own’s website and go to it. There’s a a lot of information there.
You can get a hold of Dyna, you can get ahold of Giannis via LinkedIn. It’s [00:30:00] really easy to get a hold of these guys and at least start the process. Start thinking about how robots can improve your operation, how it can save you money. Generate more revenue on the production side. Save money on the repair side.
So at the end of the day, uh, your management is happy.
Dainis Kruze: Oh, yeah. Oh yeah. We even help to do the calculations of return of investment, so it’s easier to justify, uh, with the management and so on.
Allen Hall: Oh, it’s wonderful. Wonderful. Well, Dynas and Giannis, thank you so much for spending some time with me today and showing us around this Denton facility is quite oppressive and congratulations.
And yeah, we’ll, we’ll see you on the road at some point.
Dainis Kruze: Thank you for stopping by.
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.
Renewable Energy
Artificial Stupidity?
We all understand that there are ultra-conservatives living all around us, but does anyone truly believe that our schoolteachers are ruining our society by teaching children the truth about U.S. and world history? Science? Current events?
Slavery and Jim Crow laws were bad. Fascism is bad. Our scientists are telling us that CO2 emissions are causing world temperatures to rise, destroying our planet’s capacity to support life.
Whom do these concepts upset?
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There is nothing dumb about the question posed at left. Democracies fail, falling into “banana republics” constantly. The rate at which democracies become tyrannies is so great that some of them never make the news. Can you tell me anything about the governments of Eritrea or Chad?
What makes the situation in the United States is, yes, that it’s happening here in the United States, the very last place anyone would have suspected it.
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