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Armour Edge Shields Wind Turbine Blades

Will Howell discusses Armor Edge’s thermoformed polycarbonate leading edge protection for wind turbine blades. Their solution helps to mitigate erosion, enhance aerodynamic performance, and extend blade life.

Allen Hall: Will welcome to the podcast. Thank you very much. Thanks for having me. So Joel and I have heard about Armor Edge for a couple, couple of years. Yeah. You’re based in Scotland. Yeah. And we haven’t seen you much in the United States and I haven’t physically touched it.

And of course we’re sort of tangible. We gotta play with the the product. So this is the first time now we’re here. Gotten to see the product. Yeah. Yeah. You wanna describe really what this product is for a leading edge protection?

Will Howell: Yeah, absolutely. So we are different to other LEPs out there on the market.

And really that was the whole point of our design evolution, was to try to overcome some of the traditional downfalls of some of the other LEDs that have been prevalent on blades. So. Um, yeah, we’ve been around since, um, well about eight, eight years now. And we’ve been out in the market installed since 2020.

So we’re, as you mentioned, Edinburgh, Edinburgh, Scotland is a kind of a base. So our first installs were all offshore, north North Sea, so offshore, Denmark, offshore [00:01:00] Germany. Very harsh, harsh environments. But we wanted to, to design an an LEP that was, um, really. Overcoming some of the traditional pitfalls.

So for us, that is the ease of installation, the longevity of the material, and also the a EP benefits that we, that we see. Um, as you see for the sample we have in front of us here today, it’s uh, only a small piece that we take to show just to, to, to show our clients and customers. Um, but typically the shields are 850 mil mil long.

Uh, they’re made of a, a custom thermoformed, um, polycarbonate, a SA blend. We get the material formed into sheets, and then we drape that sheet over custom design molds that are tailored for the specific blade types. And that’s how we get this perfect fit on every different blade that we’re, that we’re, um, that we have out, out there.

So let’s talk about the installation. Yeah.

Joel Saxum: Because that’s [00:02:00] a, that’s a really important one for me because on the podcast we always wanna talk about what problems we’re, what problems we’re solving. Sure. What problems you guys are helping the industry with. And one of the biggest ones with LAP, and it doesn’t matter what the product really is, if it’s tapes, if it’s coatings, if if it’s installed wrong, it’s not gonna last.

Yep. Yep. That’s, that’s the thing. So what have you guys done with this to help the technicians in the field to make it easier to make it. Last I want you to put on the line.

Will Howell: Yeah. I mean, I guess there’s a lot of technology in terms of the performance of the, of the product. Um, both the adhesive and the material itself.

But predominantly this was designed for rope access in the North Sea, so it had to be a product that the guys were. Able to handle up on, up on rope. Um, it wasn’t gonna be affected by climatic conditions as much, um, and would really lead to a faster, but also therefore, a higher quality installation because of the way that it’s put on, it’s not so much of a artisanal process that some of these other LEPs seem to [00:03:00] suffer from.

We want to. Train our technicians to deliver a high quality installation, but really you don’t have to be a master LEP installer to get our, to get our kit on, our kit on Blade. And that’s the feedback we’ve been getting from the technicians is that they find it, uh, easy to handle, easy to apply process, uh, in the field.

Joel Saxum: What does Blade Prep look like before you put it on?

Will Howell: Well, another unique. Facet of the system is because the shields themselves are custom formed from a a semi-rigid material. The leading edge of the shields themselves doesn’t conform to the existing erosion on the blade. So in terms of applying this to the blade surface, if you have existing cat one, two, or three erosion.

You don’t need to repair that and bring it back up to the original design intent. Air Aerofoil. In fact, you just need to remove the loose or flaking material. Do a final clean with an with an IPA. Then you’re ready to apply the adhesive into the target area. I. Draw the adhesive down with our custom tooth [00:04:00]spreader and then apply the shield straight on top.

So you’re actually using the, the high performance MMA as a high build filler behind the shield itself,

Joel Saxum: basically like, uh, like if you’re setting tile.

Will Howell: Yeah, very similar. Very similar. You scrape the mud down and it

Joel Saxum: creates a couple paths

Will Howell: and, exactly, exactly. The adhesive itself is very high performance, so the

MMA that we use has got a very high gap fill. Indeed. It can gap fill up to an inch if you had some severe holes on there without overheating. Um, but it can also be installed within. Any humidity, any dew point is indifferent to those conditions, as well as from freezing point right up to very high temperatures, kind of 110 degrees Fahrenheit.

Um, and we’ve, we’ve seen those conditions we’re installed across four different continents now, majority starting over in Europe, offshore, and now we’re. Some North India. We’ve got some in Southern Australia, and now the states, the past couple of couple of seasons where Iowa, Wisconsin, [00:05:00]Michigan, up in the north are kind of colder climbs as well as the southern states, Texas, Oklahoma, New Mexico.

The polycarbonate is slippery. It is. Yeah. Yeah. So does it accumulate ice? We haven’t had any specific testing on that, but we haven’t had any negative reports either. We’ve been less, we’ve been, we’ve been, we’ve been out there in the field now for five years. We’ve never lost a shields due to de bonding, we’ve never had any damage to any shields reported to us.

It’s a very resilient product, so we don’t believe that I. Has a particular attraction to the material, no worse than a traditional top coat. Um, we’ve actually been speaking to the guys from phase break who, who you’ll know with their nine ice products and they’re happy that you can apply nine ice over the top of this if you wanted to kind of double up that protection.

Allen Hall: Yeah, because that, that does make a lot of sense. If, if we’re talking North Sea and Iowa, those are two wildly in different environments. But the research I’ve done on your [00:06:00] material. I, I, I probably saw your early 2020 is when I first, I remember seeing Armor Edge and thinking, okay, these guys are onto something.

Knowing a little bit about leading edge rosn on aircraft and how we deal with it there. Mm-hmm. The technical details made sense to me. I hadn’t seen it in a shell form. Oh, there we go. Yeah. Yeah. Okay. So this, this makes a lot more sense now. So then when you actually get on a blade offshore, which would be the probably the ideal case because the return on investment is like instantaneous on these bigger turbines that you’re just, you’re just doing very little prep at all.

Then you’re just basically knocking off the little particles that are maybe hanging on applying MNA and then just. Starting where from the root working down, if we go from the tip up, we actually work

Will Howell: from the, uh, tip. Yeah. So one of the facets of our system, compared to the traditional soft shells or the tapes, you don’t have to manipulate and stretch the material over the nose of the, of the, uh, [00:07:00] blades.

The first shield is actually a, a section with a pressure suction side and a closed end. So it simply fits over the top of the tip. Like a suck gives you a very Exactly. It gives you a very. Solid boot to kind of start from, and then you work in series from, from there in sections around 850 mil long, working in the direction of the of, of the route.

Our customers have different lengths of application that they like to work to. We work in sections, but typically around 20% of the blade is, is kind of what we cover. Okay. Yeah. I, I

Allen Hall: wonder how far they were gonna go inboard, because I’ve seen some where they go really far inboard, like six to

Joel Saxum: eight meters.

Yeah.

Allen Hall: Yeah. So you’re, you’re not going all that far. Yeah. Typically.

Will Howell: You know, on the onshore machines here, some of the typical GE blades, the 56.962 point twos up at the 10, 12 meters or so. Okay. It’s, it’s just kind of a typical Okay. That

Allen Hall: makes, that makes sense. Then, so the, the process goes clean the blade apply MMA, put these [00:08:00] sections on, do the interlock, and what do you do with the trailing edge?

Will Howell: Yeah, absolutely. So again, it’s a. An issue that we’ve seen on other, on, on other systems of either one really long piece, which is almost impossible to handle with a pair, a pair of texts, or having many separate pieces with a complicated join that leaves it very exposed. Our sections are formed and then they’re very accurately CNC cuts, and we have male and female features on either end that interlock with, um, on, on two sides of the, uh, of the leading edge cord.

And so the technicians can’t get them the wrong way round. They made up completely butting against each other, leading to a very flush flash. Fit over that leading edge. Leading edge section.

Joel Saxum: Yeah. ’cause I could, I could picture like if something like this wasn’t here and they were just flat, like they’re kind of like it walking off Yeah.

Kind of getting wonky on the late edge. But this is gonna keep ’em locked in.

Will Howell: Exactly. This is alley. And so that just, you just working, working sections towards the, towards the roots, the adhesive that we use. Even though it’s an MMA, which [00:09:00] traditionally there have been some quite brittle MMAs on, on the market, we’ve, we’ve worked to find a very flexible and com and compliant that actually works as the sealants as well.

So you apply the shield, you apply pressure to the shields from the, from the leading edge, working down the pressure and suction side. You’re expelling adhesive down the trailing edges, and it’s that you are then fairing off to seal and also give you a weatherproof seal. And a aerodynamic chamfer as well, or just on that trailing edge.

The material on the leading edge typically starts around two mil, and it naturally tapers to about one mil on that, on that trailing edge. But we’re trying to minimize that as much as possible during the installation process. Sure. So 80 thousandths of an inch to under 40 thousandths. That’s pretty good.

Joel Saxum: Yeah. Yep. Ly ly. You mentioned at the beginning of kind of the, of us chatting here that also it’s creating a great aerodynamic edge. So have you guys actually validated like a EP increases from eroded blades?

Will Howell: Absolutely. [00:10:00] So, um, I mean, typically in terms of. The standard repair categories, we would consider anything that’s category one could be anything from zero to 1%.

Loss of a ap. Category two could be one to 2%, and category three could be up to three to 4% of AP loss. So you could really be losing significant amounts of power if you let your blades get up, get up to there. So we’re trying to educate our customer base to say leading edge protection is not just to protect the structural integrity of your blades.

You are, you are actually losing generation here, so. Applying an LEPI think the industry has maybe been a little bit kind of, uh, overzealous in their, in their claims. I would say if you are sticking anything to an air of foil, there may be some form of negative impact, and we have to accept that. We’ve conducted our studies though, both CFD and wind tunnel testing, and we can provide a report to any of our, any of our customers, showing an expected loss of half percent, so about negative 0.8% or so of a, of AP loss [00:11:00] when you apply it to a Virgin Blade.

However, when we see in field installations, you’re applying to an already eroded blade. So in fact, we typically see an AP uplift, and that’s what our customers see. Um, and it’s not only that initial day one increase that they’re seeing, but because we’re working with a polycarbonate instead of the traditional coatings or TPU tapes, the TPU tapes, tear and fisure, and they get that really rough surface, which has got a huge impact on a p.

Can even lead to noise complaints and flapping and all those sort of bad things that we don’t want on our blades. And so when a polycarbonate erodes, it’s more just like a, a smooth surface. Um, it doesn’t have those fis, those gaps that pitting. And so even during the life cycle of the erosion on a piece of arm edge material, you’re not seeing that same.

A EP hit.

Joel Saxum: So, I mean, a really important thing in LEP, like we’re in the states now, we’ve got 10, basically 10, 11 year life of a turbine. Yep. So we want all of our products to last that long. Right. Absolutely. With [00:12:00] PTC credit stuff, but offshore not the same story over, like in the North Sea, they want those turbines to last as long as possible.

Absolutely. Yeah. Yep. What I mean this, when I look at this, I go, I don’t. See this? I don’t see this wearing out. Well, what are you, uh, what’s the, what’s the expected lifetime of something like that?

Will Howell: So we’ve conducted brain erosion testing both within the UK and, uh, with our partners over in Denmark and.

The rain erosion testing produces a VN curve. You then apply a, uh, traditional North sea conditions, weather conditions to that VN curve, and we’ve seen the calculations there. Give us just over a 50 year lifespan, 5, 0, 50, 53 years. Yeah. Yeah. Um. You know, that’s on just a very basic rain erosion test test data.

So your mileage may vary as they say. Yeah, yeah, of course. But look, that gives us the confidence to go out into the market and say, we are selling a products that we expect to last a lifetime of the, of the blades. Yeah. So what, it’s one fit product.

Allen Hall: What turbines do you have molds for right now to, to make these pieces?

Uh, we’ve got,

Will Howell: I [00:13:00] think over, over 40 designs in our, uh, library. Library now. So we’ve, we’ve gone out and scanned as many blades as we can. We. Conduct a, a laser scan, um, to capture the geometry. We then work with a, a tool maker to, to create the tooling and then we mold the parts from there. So yeah, over 40 different models.

Predominantly the Siemens vest as now roving the state is a lot of, of the big GG blades. So anything from the kind of. Yeah, one x and two x PLA platforms we, uh, cover. So we’ve done I think over a thousand blades now. We’re, um, getting really good, really good feedback. So yeah, we can produce parts within a few weeks for the majority of the popular machines out there.

Allen Hall: Wow. Alright. That’s great. For operators, that is particularly offshore. And back to Joel’s point, if you need a turbine to be operating 20, 30 years, you need those blades to be there working. It is time to invest. You don’t do it at year 15 trying to get to 20. You wanna do it at year four, early.

Will Howell: [00:14:00] Exactly.

Early. And look, I mean, we’re, we’re actually already in conversations with the, a few of the bigger O OEMs about, um, about factory fit trials, because that’s the, that’s the, the perfect opportunity to get your blades fully protected before they even, they even fly. We have our first. Factory fit trial, um, should be next, next month, starting, starting now with one of the, one of the bigger OEMs.

Um, and we’ve got a couple others who are really interested in that, so it may actually be even a, a revised process when it comes to factory fit and we can discuss how to optimize that further to improve their, their workflow. But they can then still benefit from the performance of the Armor edge system.

If I am

Joel Saxum: a wind turbine operator owner, I’m doing that. I’m putting LEP on in the factory. I mean, if, if someone goes, if, if I go to the. My, my local friendly turbine salesperson and I say I want LEP in the fa. I want all the options given to me. I want an upgraded LPS system. I want [00:15:00] LEP put on in the factory.

I want all the bells and whistles ’cause I don’t want to deal with it. Right. I think that’s why you start to see, okay, like a product like this and you mentioning like Iowa, not usually, you wouldn’t think of Iowa being a crazy leading edge erosion place, but it is. We see it all the time, but for me, this is like, I’m going right to something like this.

’cause I want it to be done. I don’t want to deal with it anymore. I don’t want no more phone calls. I don’t wanna deal with any LEP issues.

Will Howell: Yeah. Yeah. I mean, even on, even on day one of the install, we feel that. We’re already offering a better value proposition, even compared to the traditionally very cheap coatings, for instance, where you can pi pay a relatively low price per meter for the materials, but even then you might have to do a few coats and it takes quite a long time.

It takes a long time to to cure.

Allen Hall: As an operator. It makes total sense. Yeah, yeah. To do that. Yeah. Do it.

Will Howell: You know, you’re, you’re talking protection of the blade from structural damage at that point.

Your improvements of the a EP, um, we’re the. OMO and m and s conference here today. [00:16:00] You’ve got less guys having to go up on blades, risking themselves to actually do these repairs, and the just the repeated cycles of intervention that we see in the industry for LEP and blade repairs on the, on the, on the leading edges.

Hopefully we can help to mitigate some of that.

Even if you have maybe some. Um, OEM specified, LEP from the factory. That maybe doesn’t last very long, but you are tied into a five year warranty period, or a service contract then. Yeah. We’ve been dealing with, with lots of, um, owners who are coming to the end of that period and thinking right now’s the time to get a, a high performance LLEP on.

They can specify arm reg from a, a basket access, which I think is the fastest we’ve measured so far. You can get a machine completed by a two man basket. 10 meters per blade in about a day, a day and a half per machine. So it’s really quite a rapid install. And of course that’s taking into account the benefits of.

Not having to repair that blade leading edge, not having to [00:17:00]manipulate difficult materials when you’re up on rope board basket.

Allen Hall: So where would an operator or an OEM go to learn more about

Will Howell: Armor

Allen Hall: Edge?

Will Howell: Well, um, our website has plenty of information, so that’s just armor edge.com. Um, where. Yeah, based over in Edinburgh, Scotland, if you’re ever over there and want to come, want to come say hey.

Um, we also do a lot of work now in the states with a number of different, um, I ISPs over here and we are happy just to try and get the name out out there more. I mean, you guys alluded to it, we’re not as well known, uh, kind of brands over here, but. We are very well established in terms of the supply base already and it’s about informing the owner, owner operators and informing the installers who are working with materials.

Um, and yeah, we’re getting really positive feedback to anyone that we’ve been dealing with. We gotta remember that they’re in Scotland. So Armor Edge

Joel Saxum: is AR MOUR. That’s

Will Howell: right. I have had it mentioned a few times this week. Yeah. Yeah.

Yeah, so check out Armor Edge online, learn about [00:18:00] more, learn more about their products, and if you need more information, you can get a hold of Will via LinkedIn.

Yeah. Thank you. Appreciate it. Thanks, will. Great. Cool. Easy. Nice. Done. That was good.

Allen Hall: Nice. Okay. That’s good. That was great. Good ton of information given away there. I hope that wasn’t.

https://weatherguardwind.com/armour-edge-shields-blades/

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And Mexico Will Pay for the Wall

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One of the most remarkable characteristics of Donald Trump is his shamelessness.  No matter how many lies he gets caught in, he’s always willing to tell one more–one that’s even more outrageous.

One would think that he and his supporters would eventually reach a limit, but the answer is clearly that such a limit does not exist.

And Mexico Will Pay for the Wall

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Dogger Bank Wake Lawsuit, EverWind Hydrogen Farm

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Dogger Bank Wake Lawsuit, EverWind Hydrogen Farm

Rosemary previews Pardalote’s new hands-on blade repair course. EverWind’s Ocean Lake, Canada’s largest wind project, will feed a green hydrogen and ammonia plant in Nova Scotia rather than the grid. Plus BP’s exit from an offshore project in Japan, and the wake-effect lawsuit pitting SSE, Equinor, and Vårgrønn against RWE’s Dogger Bank South.

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!

The Uptime Wind Energy podcast, brought to you by StrikeTape. Protecting thousands of wind turbines from lightning damage worldwide. Visit striketape.com. And now your hosts

Allen Hall 2025: Welcome to the Uptime Wind Energy podcast. I’m your host, Allen Hall. I’m here with Matthew Stead, Yolanda Padron, and Rosemary Barnes is back this week.

Rosemary, you’ve been to a number of training courses over the last couple of weeks. The first off was GWO. What was your experience at GWO training?

Rosemary1: It was the fourth or maybe even fifth time that I’ve done it. Um, I did it a few times in Denmark and then, uh, this is the second time doing it in Australia. also, this was my first time doing first aid in Australia. Last time they did GWO here, but my first aid was still valid from Europe, so I, I didn’t redo it. And it’s like so much about [00:01:00] snakes and spiders and jellyfish But a good, good rule of thumb, not 100% accurate, but good rule of thumb, if it is something from the ocean that stung you, then you put something warm on it, and if it’s something from the land that stung or bit you, then something cold on it,

Allen Hall 2025: well, how often do you usually take GWO training?

Rosemary1: You gotta do it every two years to be valid. I don’t do it every two years because, um, if you do it every two years, like within two years, then you can do the refresher course. So that’s three days instead of four However, um, because I don’t climb constantly, like often it will be six months or more in between climbs, I’ll just do it before I know that I’ve got a climb.

all the other people except for one were technicians who, you know, have been working for a while.

So they’re also doing the full course, not the refresher. So they get a little bit more practice than I do. But, um, it’s just not often enough. Y-you know, like every time I go it’s like I, I really feel the need to have the refresher, um, because I’m just not fully on top of it. ‘Cause it’s [00:02:00] not just that you need to know what to do. You need to be able to… Like if you need to use it, you’re gonna be freaking out, you know?

This is the worst thing that’s probably ever happened in your life, and now you’ve gotta remember all your training. It’s like you want it to be actually second nature to some extent. So yeah, first day is manual handling, which is v- you know, very– That one’s very easy and I would be happy to never do that again.

Like I will always remember that. Um, then you got fire, um, fire safety awareness, and that one’s just fun ’cause you just get to, um, light fires and put stuff out then first aid, which I definitely always want a refresher on.

The CPR dummies at this place, they had lights, um, and it lit up green if you were doing it right, and I haven’t used a dummy that was so advanced before, so that was quite good. I realized I wasn’t pressing hard enough. and then yeah, last two days is working at heights training, which is the most intense ’cause you got your harness on all day and, um, you know, climbing up and down and rescuing people.

this was Rite Training in Goulburn, and, um, the [00:03:00] instructor’s name was Claire. highly recommend doing that one.

Allen Hall 2025: Is that a general requirement in Australia that you have GWO before you can climb?

Rosemary1: Like, yeah, they will sometimes, um, let you climb if you are babysat by people. I would not recommend other engineers, like if you’ve never climbed a wind turbine before, like I would really not recommend that you just go up with a team and haven’t done the training because you do need to be able to use a ladder safely and, um, you can, y- you can easily, like even inside the nacelle, you could easily hurt yourself really badly if you’re used to working in an office, uh, you’re upping your danger level by, you know, like many, many, many times by going up a turbine and it’s just something that you gotta take seriously.

Allen Hall 2025: How busy are the courses in Australia? Are a lot of technicians trying to get in and get trained?

Rosemary1: No, it’s people that have a job that are getting trained. But there were heaps of techs in this course. There were maybe eight or so, which is also part of the reason why it took a really long time.

Allen Hall 2025: So [00:04:00] this week, as we record, y- you’re presenting a blade repair course for engineers and technicians. a completely new area that you’re, uh, going into in terms of offering advice and expertise that it’s really hard to find on the planet. It’s probably a, a, a busy or, or requested course, I would imagine, in Australia, where you just don’t have access to a lot of the manufacturers.

Rosemary2: it’s a, it’s a course for just for engineers or technical type people, um, but including hands-on stuff. So the way that I I forced this to come into being was just the last five years. I, um, you know, I started working a lot on wind turbine blade repairs and, um, people would ask me, you know, “Have these repairs been done right?”

And the thing is that the only repairs that I had anything to do with when I was working at LM were weirdo ones, right? [00:05:00] Where the normal, like a technician couldn’t, couldn’t handle it. It was outside of, um, yeah, their, their standard, uh, kind of repairs that they can do for whatever reason. and now in the work that we do at Part Load, it’s primarily normal repairs, and I just didn’t know exactly what technicians know. You know, how do they, how do they know whether they can repair it or not? What do they know before they go up there?

When are they calling the engineer? Um, all that sort of stuff, like the normal stuff. eventually it became less about me learning, ’cause like I said, I kind of picked up most of it. Um, but now I’ve got staff that I’m training up to be, uh, you know, composites engineers and to work with these kinds of issues. There’s a lot of repetitive tasks involved in what we do when we, like, assess the condition of a wind farm.

A lot of what we do is look main- manually looking through photos and thing- if things are classified right or not. I [00:06:00] Found this guy from Direct Wind Services, Jurij Eska. He’s a blade engineer. He’s worked in Europe and then come back to Australia, so a little bit like me. And, um, I just worked with him on a few projects and I’m like, “Oh, okay. Well, this guy, uh, he really gets it.” And I asked him, “How do you, how do you train your technicians?

What course do they do? Maybe I can do that course.” And he said, “Oh, we train them ourselves.” And so then I asked him to put this course together. So where we started off the course yesterday, that was, um, uh, an indoor session where I was talking through how are blades designed, uh, certified, tested, manufactured, um, what kinds of manufacturing defects can you see and what do they do about them in the factory?

‘Cause you know that they’re doing a lot of repairs in the factory already before you ever see a, a brand new blade. and then the next three days we’re going to be working on, um, yeah, grinding and [00:07:00] infusions and a bit of a, a bit of theory about, um, composite repairs.

Allen Hall 2025: What do you feel like are those key skill sets that engineers should know how to do, maybe not as well as a, a professional technician that does it a lot, but at least at a beginner’s level should be able to complete them before they start repairing blades on their own and giving advice about how to repair blades?

What, what are those key items?

Rosemary2: part of it is that I want them to be able to understand what is a bad damage and what’s not a bad damage cause you look a lot at images from the outside, but it’s really about what’s on the inside and how deep it goes is the real thing.

So, um, it’ll be about learning, you know, developing some judgment about, um, how bad it can be and how bad it can look on the outside. We’re not gonna be looking at so many real damages ’cause like obviously we’re just dealing with pieces that are in the, um, in the, uh, workshop and Yuri has [00:08:00] made some samples for us, um, purposely made them badly so that we’ve got some, you know, damage to find.

Allen Hall 2025: Are you addressing carbon fiber at all?

Rosemary2: Uh, I actually haven’t asked about that. I don’t think so. Carbon fiber is, um, is a real pain to work with because it’s conductive. Like, even grinding it makes a bit of a hazardous work environment. We did talk a little bit about the different materials yesterday and, um, about pultrusions. And actually, it turns out Yuri used to work somewhere where they, uh, manufactured pultrusions, and I had always, I was always under the impression that a pultrusion is, you know, like, perfectly s- perfectly straight.

That’s the point. And he’s like, “No way.” No way. There’s waviness in the pultrusions

Allen Hall 2025: And on March 3rd through 5th at WOMA 2027, Rosie, you’re gonna give part of this course as part of WOMA, right?

Rosemary2: Little, little mini course. We’ll have to decide what, what makes sense to include, ’cause it was… Yeah, I went through really a, a fair [00:09:00]bit about blades yesterday, you know, like why they are shaped the way that they are. So we had to talk about aerodynamics and, um, why they’re made of composite. So we had to talk about, you know, like composite materials, like how, how they, how they work So I don’t know if, uh, people wanna write in comments that m- we should, we should do some sort of, um, poll beforehand to see what are the topics that are most interesting to people, ’cause I think we’ll have a half day, right? So we’ll need to be, we’ll need to be focused.

Allen Hall 2025: the description of repairs and what repairs should look like could be tremendously valuable. Everybody who has seen a repair always wonders, “Was that repair done right?” And s- and if you can have some general tools to know, like, “Uh, maybe there’s something not quite right here,” or, “That looks like a solid repair,” that would be a tremendous help to the industry, p- particularly for asset managers

Rosemary2: Yeah. And you know what I think is even more useful than being able to pick out when it’s wrong is to be able to know when it’s right. You can– Y-you know, like it is so– [00:10:00] It’s such a relief. Like it takes such a mental load off you when you’re just like, “Yeah, that’s all, that’s all good. That’s normal. Okay, I know that that– I knew that that would happen, so this is not a surprise.”

‘ know, once you know you can make that judgment, you can do it very quickly and focus your attention where it should be, so you don’t need to stress for an hour over every repair. You’re just like, “Yeah. Good, good, good, good, good.” And then, “Mm, please explain why you have chosen to not, not repair this, but just put a Band-Aid over it.”

that’s the goal of this training is to get everybody, y-you know, technical people, not people who wanna ever be a blade repair technician. They’ve got their own training that covers what they need to know. But this one is just, yeah, getting people like asset managers or my employees to learn what they need to know about composites, given that they have already got a strong engineering education.

So, um, you know, they know a lot of the stuff, but just need to know the composite-specific stuff and wind turbine blade-specific stuff

I will run this course again, by the [00:11:00] way, ’cause there was a lot of people who wanted to do it I couldn’t fit in. So it’ll happen at least once. I’ll keep on running it until everybody that wants to do it has, has done it. But, um, yeah, feel free

to get in touch

Allen Hall 2025: So if you wanna attend Rosie’s short blade course at WOMA 2027, just visit woma2027.com and register today

Allen Hall 2025: [00:12:00] Well, over in Canada, they just approved a, really a wind farm big enough to power a small city, and almost none of the electricity is going to the grid, which is a very interesting aspect to some of the things that are happening in Canada at the minute.

So up in Nova Scotia, uh, they’ve conditionally approved the Ocean Lake Wind Project. This’d be the largest wind farm in the province’s history. Up to 158 turbines will rise, uh, generating as much as 1.2 gigawatts of power. But this power is not headed to households in Canada. Nearly all of it will be feeding Everwind Fuels’ green hydrogen and ammonia plant at Point Tupper, where clean electrons will become a fuel that can be shipped across the ocean to Europe. And Matthew, there’s been a lot of [00:13:00] projects like this in Europe that have stopped more recently, particularly in northern Europe and up in Scandinavia, uh, on the hydrogen side. Or at least they’ve slowed them down. Canada seems to be going into that breach maybe to fill that void. And is there a marketplace for this to occur up in Canada?

Matthew Stead: Yeah, I think it’s very interesting. Um, you know, like you say, a number of canceled projects, and in Australia there’s been numerous canceled projects. So I like, um, the analogy or use of the term hopium rather than hydrogen, um, where, um, everyone’s hoping hydrogen will be the answer. Um, although, you know, what I, what I’ve read and understood is that, um, you know, the commercials just don’t really stack up and, um, yeah. So in terms of South Australia anyway, um, there was some major, um, hydrogen, uh, development planned with, um, you know, it, it never stacked up. So, you know, it sounds like a great [00:14:00] idea, um, but I’m not sure that the commercials will ever stack up unless you’ve got that guaranteed offtake for the, for the ammonium

Allen Hall 2025: Yolanda, what kind of uphill battle is this to get this wind farm up and running knowing that it’s one customer and that commercial market is a little shaky at the minute?

Yolanda Padron: what we saw, they have a lot of ca- caveats, right? So they’ve, they need to secure the customers before they start building and before they do anything, um, behind the meter. But it’s, I mean, it’s, it’s a pretty big wind farm, and it’s pretty far up north. But I mean, we, we talked to someone in, in northern US today who was having icing issues.

So I mean, of course we know Canada is no, no stranger to that, if they do make it work, I think it’d be really, really exciting to, to have sort of one technology power another, um, instead of just what we’ve been hearing a lot of the potential data centers and, and just wind po- [00:15:00] powering data centers.

Matthew Stead: Why not data centers? You know, seriously, like you said, Yolanda. why not go something that does have commercial demand?

Yolanda Padron: we’ve talked a lot about the potential of da- data centers, right? And we’ve talked a lot about people wanting to do them. Um, but there’s also a lot of talk of potentially doing data centers up in space and a lot of talk of maybe what if we do it offshore or, you know. And so I think there’s a lot of what ifs with data centers.

Of course, there’s a lot of what if with this, but just from a technology standpoint, I think this is really intriguing to have something that’s, that’s a little bit even more out there than what we’ve heard so far

Allen Hall 2025: Is it a build it and they will come type of s- situation here that hydrogen and ammonia may be the, the first offtake, but realistically, if that doesn’t work out, they can still connect to the grid and feed Canada, feed the Northeast of the United States or something else

Matthew Stead: Also, um, like Japan has [00:16:00] also expressed strong demand for, um, ammonia, and so, you know, they- they’re on the East Coast, aren’t they? So, you know, shipping it from East Coast to Japan is not gonna be so, so easy. I stick by what I said before. It’s hopium. it’s not a plan

Allen Hall 2025: I just saw an article today talking about Airbus continuing on with a hydrogen aircraft, and I think they were gonna work with a Japanese firm to work on that together. Six months ago I thought that died, but maybe it’s still in the offering. Maybe there’s an offtake for hydrogen. B- besides the, you know, replacement for some of the, uh, more unpleasant gases that are used in steel production and in some other industry things, maybe part of this is airplane fuel.

Which ammonia is one of those offerings also, right? The, there’s been a number of efforts to turn ammonia fuel into essentially jet fuel. They configure the engines to burn ammonia, which is a possibility. It does seem remote though, [00:17:00] honestly. There doesn’t seem to be a huge pull for hydrogen, and there’s not a, a major market for ammonia at at least at the moment.

So I don’t know. It, it’s… When you’re talking about gigawatts of capacity you’re gonna build, you, you hopefully have an offtake

for it

Yolanda Padron: if they designed it for it being not connected to the grid, right, it just is kind of like a behind the meter thing, and then could they later retrofit it into there? Like, how would all that permitting and everything

Allen Hall 2025: I–

well, that’s a great question. I– There are a number of, uh, connections between the United States and Canada at the moment. guess is that when they place this wind farm, they have that alternate route lined up, just like any wind farm in here in the States, that you’ll find them real close to high-voltage transmission lines.

Generally, those are the easy ones because transmission lines cost money and take time for permitting. I’m not sure Canada has those kind of restrictions, right? But Nova Scotia is not the easiest place in the world to do heavy construction work, just the [00:18:00] nature of Nova Scotia. It will be fascinating to see how they progress with this, but it’s something to keep an eye on because a lot of other projects like this have slowed down

Matthew Stead: Do you remember when some of the OEMs were talking about, um, putting electrolyzers on their offshore wind turbines? So the, the theory, the theory was you’ve got offshore wind turbine, you don’t connect it to the grid standalone, um, and you generate hydrogen or, uh, possibly ammonia on the actual wind turbine.

And then every now and then you just decant it, you know, drive up with a boat, you know, plug in the hose, and then suck out the hydrogen or ammonia. So, um, yeah, once again, all of those have gone quiet, haven’t

they?

Allen Hall 2025: speaking of Japan, a global oil giant is walking away from the Japanese offshore wind project, uh, but the project’s not dying. BP has told its Japanese partners it intends to withdraw from a wind farm planned off Yamagata Prefecture, uh, apparently worried about [00:19:00] profitability. The 450-megawatt project sits, uh, just off the coast, and it is led by trading house Marubeni, which says it will press ahead without BP.

Kansai Electric and Tokyo Gas remain on board also. So BP’s exit follows really a, a brutal year for Japan, where Mitsubishi has, and some others, have pulled out of, uh, at least three projects so far, uh, over rising construction costs, and I think a lot of that’s tied to inflation. Uh, the ambition’s still there for, uh, for a number of companies, but it’s just getting harder and harder to do projects in Japan.

Is this just the nature of the economy in Japan at the moment, or is this more about Japanese policy on the offtake,

Matthew Stead: I, I’m not really deep into the details but, you know, it just appears to me like a blip. I mean, there, I think there’s a lot of commitment in Japan to, you know, carry [00:20:00] out their offshore developments and I, I think this is probably more just a blip, um, and a little, you know, internal corporate, you know, argument rather than a sustained issue on offtake agreements and so forth

Allen Hall 2025: Well, Yolanda, how hard is it to keep partners on a wind development in general? Are there a lot of moving pieces there until the turbines hit the water or hit the

earth?

there’s

Yolanda Padron: I think a lot of moving pieces, but not, uh, I haven’t seen a lot of changes once it’s been publicly announced and everything’s, you know, everything’s been signed and everything. Um, I do think this is really interesting. I know we’ve talked a lot about, about having, about the idea of like sometimes people think wind’s really expensive, and the way that we’re gonna make wind work is just making it cheaper for everybody and just optimizing it as much as possible, um, and, and just being, having the turbines be as resilient as possible, right?

And I think such a strong player just backing out maybe [00:21:00] will incentivize some of the people in Japan to sort of try to see how they can optimize it a little bit more. I’m really excited to see it. I don’t know. It’d be… I think it’d be a nice it

Allen Hall 2025: Isn’t the bonus to offshore wind the price stability? Although the price may be higher today than you may be happy to pay, the stability of that price is a huge leverage point when you compare it to things like oil and gas or natural gas, um, in particular, which are highly volatile, that for electricity, at least you have this fairly steady source at a fixed price that you can plan out 10 years, 20 years, 25 years, maybe even 30 years. And as batteries become more prevalent on the grid, that the math even gets better over the years. Isn’t that the bonus? And, and if [00:22:00] everybody can focus on the long-term effects to the economy is where all the action will be?

Matthew Stead: Yeah, I mean, when I first, um, started looking into wind, you know, 10 plus years ago, I, I won- wondered why. Why would you build offshore with all that expense? And then, you know, it became clear to me just around the, um, you know, the diversity, you know, the, the fact that you might get more wind at times that you don’t get onshore wind, and the fact that it’s more consistent.

Um, yeah, and, you know, so those… I- it’s really a trade-off, isn’t it? Between the capital costs and the, um, more reliable, more consistent, um, offshore wind. So I think, you know, I, I was convinced at the start, I thought it was crazy, but then obviously it’s, it’s a, it’s a… it makes sense

Yolanda Padron: Yeah, I agree. And I think, uh, depending on where you’re having your offshore wind farm, you run into things that you maybe haven’t run into before, right? I know onshore we run into a lot of things in the [00:23:00]US and Australia that we, you know, the, the turbines just maybe weren’t designed for, or there wasn’t a lot of research being done because it was being done in Europe and, and the conditions are really different.

Um, and just the same way, you know, the sea is different in different places. There’s different depths. There are diff- different things that you need to worry about. but yeah, I, I completely agree that there’s a lot more generation, um, offshore. It’s, it’s bigger turbines. Um, there can be bigger, larger costs. You know, if you need to do a blade replacement or something, it, it can get, again, really expensive really quickly. But, but it’s, it’s a trade-off for sure.

Allen Hall 2025: We’re gonna take a quick break, but when we come back, we wanna talk about a place where wind is being fought over versus projects slowing down ​

[00:24:00] over in the UK, there’s a big fight about offshore wind, and not just about where wind turbines will be planted, but more about how they will affect other wind turbines.

So RWE is defending the UK government’s approval of its three-gigawatt Dogger Bank South project, which won its consent order, uh, basically a month and a half ago. Uh, but the developers next door are taking that approval to court. Equinor, SSE, Vårgrön own the neighboring 3.6-gigawatt Dogger Bank wind farm, and they have filed for j-judicial review.

Their argument is technical, but the price tag is not. They say wake effects, where one wind farm steals the wind from another due to turbulence, could cut their output and cost them between €500 million and [00:25:00] €669 million over the life of their project. That’s a lot of money, Matthew. A half a million euros is not something to ignore.

It looks like this is headed to some judicial court or maybe arbitration. Wake effects, which are actually not that well understood from what I can tell at the moment, there’s a lot of discussion and argument about, uh, how real are they or, or what effect they can have on power output. Uh, there’s a lot of money at stake, and the location of some of these wind farms is pretty close to one

another

Matthew Stead: you know, we always, always talk about, you know, AEP loss and, you know, the, the challenge is actually measuring it. And, um, you know, I’ve heard different numbers, but, you know, plus or minus half a percent of AEP loss, um, appears to me from what– in discussions, you know, the, the limit of what you can actually ever measure on a good day.

Um, I just wonder, I mean, while those numbers, you know, €500, um, [00:26:00] million is a, is a big number, um, but what is that as a percentage of the overall output of that, of that facility? Um, I, I don’t know the answer, but, you know, if, if it’s, you know, half a percent, I think you’d be struggling to, um, struggling to justify that, that wake effect loss.

I mean, you know, going back to what you said, Allen, you know, there are wake effects of some sort, but it’s a question of how much. I mean, that-that’s why aircraft don’t take off, um, too closely, isn’t it? Because there’s wake effects. Um, so it’s definitely a given, definitely a given. Um, but, you know, how much of an impact it truly is.

Um, and I mean, there’s always other variables, you know, variables in the weather, you know, wind patterns, da, da, da, da, da, da, da, and how much do this– does this actually compare to those other, other variables?

Allen Hall 2025: Yolanda, how would you even mitigate wake turbulence on an adjacent wind farm? Are there ways to do that today?

Yolanda Padron: I think the, the aerodynamics, Allen, would [00:27:00] be a lot more in your court than, than in mine.

Matthew does have a really good point. I mean, what are we… With the UK wanting to ramp up offshore as much as they want to ramp up, right? They’re not going to just cancel a large project, and they need to… I mean, it’s not, uh, there’s a finite amount of space, right? So what, I mean, what, what are you, what are you gonna do?

It’s like, it’s what, like, what happens in onshore where you, you really hope maybe that you don’t get a wind farm that’s really, really close by. Um, but you might also want to plan for it. I mean, I know of sites that have le- that lease a little bit of extra land so that way no one else can lease it, or that they can, they can use that to, to travel between turbines.

Um, and it’s, I mean, it’s, it’s kind of… Isn’t it kind of just part of it, part of the trade?

Allen Hall 2025: it has to be, right, at some point. [00:28:00] The question in my mind about all this is how much wake is there? Is it directly impacting the adjacent wind farm? Is there– are there things that can be done to minimize that wake turbulence? I think the answer is yes, but as wind turbine blade designers, I haven’t seen the same level of wake reduction that we have seen more recently in aerospace.

It’s complicated to do some of these things on a wind turbine blade. You’re mass-producing. You’re making a blade a day or a blade in a day-and-a-half timeframe. Are you gonna design this really aerodynamic tip to go on to reduce the wake on a particular wind farm? Probably not, right? So it’s, it’s– is it worth doing that versus the, the cost it would be?

So it’s gonna cost 500 million euros in loss to an adjacent wind farm. Do you put that 500 million into the design effort and the molds and [00:29:00]everything else to make these blades different? Uh, it’s a tight trade-off, right? It– from the engineering side. It may be better settled in the courts, honestly. Just it may be cheaper to do it that way.

Matthew Stead: Uh, I, I was gonna go down a different avenue. I mean, obviously there’s always curtailment. There’s always curtailment due to grid congestion, et cetera, et cetera, et cetera, maintenance. I mean, if they, if they just– when wind is coming from a certain direction, they could just de-rate and, uh, just not absorb as much energy, um, out of the wind when the wind is coming from that sector.

And so that would be a way of, um, not modifying the turbine, just de-rating it under a certain wind condition. I mean, the same thing occurs with noise curtailment all the time. Um, so there’s, there’s noise modes. There could be a, a wake loss mode. We should trademark that

Allen Hall 2025: Well, you know who’s gonna make money out of this no matter what? The

lawyers.

Allen Hall 2025: [00:30:00] Well, in this quarter’s PES Wind magazine, there are a number of great articles, and you can download the entire magazine and all those great articles at peswind.com. There’s a nice little article from Enerpac Tool Group, and if you’re not familiar with them, they make a, a number of tools that are handy in the wind industry.

Uh, and, you know, routine torque checks is kind of a pain, right? And the problem with a lot of those checks is that you have to haul around a heavy hydraulic pump to do it. And so if you’ve ever been to a trade show and seen some of these [00:31:00] pumps, it is a pain. And if you h- have to move around, especially on a w- wind site a lot, you really don’t wanna have a heavy pump that maybe is made for something, uh, more robust.

Uh, and you need something that’s portable. That’s what you really need, right? So the Enerpac Tool Group has really created this, uh, LU series they call. Which is a lightweight, portable, hydraulic pump, which is for intermittent work, which is what happens on most wind sites. It’s intermittent. Uh, so the product line director, Angie Wallace, uh, talks about this and says technician feedback has shaped this new tool, uh, from multiple carrying handles and an upward-facing gauge.

And that is a big thumbs up from me. When you put the gauge on the side of the tool where you can’t see it, such a problem. It’s like they’ve never used it. Well, obviously, the Enerpac has been talking to technicians, and they put the gauge where the technician can actually see it. Uh, and it’s designed to go through towers and, and tight [00:32:00] spaces.

Uh, so this is made specifically for offshore conditions. It’s ruggedized, and it’s a great tool. And a lot of times, Matthew, when you s- see the technicians about and some of the tools they carry, you’re like, man, that is not a good tool for this. That is, that is too much to be hauling around, particularly uptower.

It’s nice that we can see some tools that are designed job

Matthew Stead: I, I’m completely convinced. I, I don’t have much to say. Um, I mean, my, my day job is, um, you know, designing products and working out what products we’re going to, to work on, and, you know, the customer is the main voice you should listen to, um, at least in the first step. So always listen to the customer first, and I think from what you’ve described, customer first, and then develop the product to suit the application.

Yeah, so yeah, I’m convinced

Allen Hall 2025: Yolanda, you’ve seen Interpack on sites, haven’t you? It does seem like I run across them once in a while at some of the US

sites

Yolanda Padron: Every once [00:33:00] in a while. I do gotta say I love the idea of when, like, actual, like, boots on the ground people’s feedback is taken into consideration for, for anything really. And so this is, this just makes me really happy because I think a lot of times, like, as engineers, like, we love the idea of just, oh, I’m gonna do this really cool fancy thing, and then it’s just it- no one can use it, or a very specialized person has to be able to use it.

And so actually doing, you know, modifying a product so that it, it makes sense for the people using it, and I know we’ve, we’ve all talked about it a lot internally and, and we continue to work towards making it easier and easier on, on the people actually installing the product. Like, this is, this is really exciting.

Allen Hall 2025: So if you need a lightweight pump for tightening some bolts uptower, particularly if you’re offshore, take a look at this Enerpac line of LU lightweight series tools. It’s well worth it. And at that same time, you should check out PES Wind magazine. Just go to [00:34:00] peswind.com

That wraps up another episode of the Uptime Wind Energy podcast. If today’s discussion sparked any questions or ideas, we’d love to hear from you. Reach out directly to Rosemary, and don’t forget to subscribe so you never miss an episode. for yolonda, Matthew, and Rosemary, I’m Allen Hall, and we’ll see you here next week on the Uptime Wind Energy podcast.

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