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Beyond on-the-job-training for Blade Repair Technicians

Blade Repair Academy is a campus for wind turbine technicians, a controlled training environment that was designed by experienced blade repair technicians to teach others the art (and the science) of wind turbine maintenance and blade repair.

Alfred Crabtree is Blade Repair Academy’s founder and its CEO. Before founding the 4300-square foot facility about 40 miles north of Chattanooga, Tennessee, Crabtree spent more than six years performing repairs of wind turbine blades on ropes and platforms – and then developed and ran a large-scale composite training program.

If 6 years doesn’t sound like very long, consider that it is 20% longer than the average blade repair technician spends in the field.

Joel Saxum watched Crabtree’s presentation at Blades USA and had to learn more. Crabtree agreed to an interview, and this article highlights some of their conversation.

The full recording can be heard for free here and – at just 23 minutes long – it’s well worth your time.

The World Needs More Blade Repair Technicians

There’s a high rate of attrition for blade repair technicians, which bleeds expertise from the professional ranks faster than many high-burnout jobs. Consider the number of construction workers and firefighters and other physically and mentally draining careers. Those jobs take heavy tolls, but the majority of people in those and other similarly demanding roles retire from those careers.

Simply put, there’s just hardly any reasonable comparison.

wind turbine tec training academy

For one thing, the US Department of Labor doesn’t even list “Blade Repair Technician” as a job. “’Blade repair’ is one line item in the (description for) Wind Turbine Technician,” Crabtree said.

And that’s just the start of the problem. When the job doesn’t exist in the Department of Labor catalog, the career path can only be described as unclear.

“That’s not incumbent upon (the Department of Labor),” Crabtree points out. “It’s incumbent on the industry to create that description.”

Crabtree, Blade Repair Academy, and others in the wind energy field are working with the Department of Labor to create a listing for the occupation. It’s one of several initiatives that are happening simultaneously and quickly, out of necessity, in an industry that is being forced to standardize and professionalize while it grows to meet increasing demands worldwide.

While the IRA bill includes an item to help fund apprenticeship programs for just the type of training Blade Repair Academy provides, Crabtree notes that government funds or tax breaks can be a double-edged sword. There have been numerous examples of training dollars being exhausted when large corporations quickly establish in-name-only ‘apprenticeship programs’ that are essentially meaningless because they do not adhere to industry-wide protocols. While deserving clients sometimes receive the benefits of such efforts, the programs do not advance the industry or the blade repair profession.

How Do Blade Repair Technicians Learn Their Jobs?

Whether it’s skillfully handling a grinder, reading a work order, or working at heights, existing training programs really don’t accurately reflect what a wind turbine technician deals with in the field.

And yet, on-the-job (and often, on-the-blade) training is pretty typical in the wind energy world.

“It can take half a season to find out the quality of work, which is terrifying,” Crabtree said.

That is why Blade Repair Academy focuses on hands-on learning by doing, repetitively, in a controlled environment.

blade repair academy images

“When you’re upon a blade, you have very little cognitive bandwidth left,” he said. And up on that blade, there are so many steps you need to do, in just the right order, to keep yourself safe, remaining mental capacity must be devoted to completing the task at hand.

Because the Blade Repair Academy founders have practical experience in the field, they know a few things that may seem counterintuitive to a hiring manager. Things like, “the techs who are really, really good at their jobs may not be great teachers,” Crabtree said.

In fact, the techs who are great under pressure are often head-down, get-it-done types who are rarely inclined to take the time to instruct someone else or let them demonstrate newly-learned skills. Adding to the stress of the situation, quite often time-frames are severely shortened due to weather conditions and other uncontrollable factors.

A variety of classes are offered, focusing on the fundamentals, on working with composites, on applying new methods, requirements and technologies, and on more specific repair techniques for LE/TE bond line splits and transverse cracks to spar cap and tip repairs.

In addition to classes, employers can send new hires to the Academy to be vetted or rated before going on assignment. Otherwise, there are few if any ways to assess competency until a blade tech is in the field.

Wind Energy’s New Technology Demonstration Center?

Crabtree said the Academy is also finding increasing interest in using the campus as a technology demonstration center. Companies that need a controlled environment to trail new materials and technologies, such as UV curing and infusion, have been pleased with the ease of use of facilities at the Academy.

Confidence is gained by working through the unknown, and this can involve mistakes. – Blade Repair Academy

For more information visit the Blade Repair Academy website or contact Crabtree on LinkedIn.

Photo credit: Blade Repair Academy

Beyond on-the-job-training for Blade Repair Technicians

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Impressive Levels of Stupidity

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Without doubt, stupidity is part of Trumpism, but it’s only a part.

Meanness is also essential.  People with any real compassion for others don’t have what it takes to be a member of the MAGA base.

Impressive Levels of Stupidity

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Power and Corruption

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As Aristotle said (plus or minus): Only people who do not seek power and qualified to hold it.

In retrospect, the United States hadn’t gotten burned too badly until Donald Trump came along.

Power and Corruption

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Judge Ends Pentagon Wind Freeze, RWE Exits US Offshore

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Judge Ends Pentagon Wind Freeze, RWE Exits US Offshore

Allen covers a judge lifting the Pentagon’s wind freeze, RWE’s $1.22B US offshore exit, and TotalEnergies buying Shell’s European renewables.

Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTubeLinkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!

Good Monday everyone.

You know … there is an old saying. When one door closes … another one opens. Well this week in wind energy … a whole lot of doors were swinging.

Let us start in Washington. For months … the Pentagon had quietly stopped reviewing wind energy project applications. More than a hundred and fifty onshore wind projects … stuck in limbo. The Defense Department claimed that drones in Ukraine had changed the game. Wind turbines … they said … could blind radar to incoming threats. So they hit the brakes.

But on Thursday … a federal judge said … not so fast. Judge Karin Immergut … a Trump appointee no less … issued a preliminary injunction. Resume the reviews … she ordered. Follow the law Congress wrote. The law gives the Pentagon seventy-five days for a preliminary review. As of late July … not a single one had been completed since the halt began in May. When government lawyers were asked to name one project they had reviewed … they could not name a single one. The judge told them plainly. If you want to change the rules … go ask Congress.

Now … while one arm of the government was being told to do its job … another arm was writing checks. German energy giant RWE … handed back its American offshore wind leases. New York. California. Louisiana. In return … the U.S. Department of the Interior cut RWE a check for one-point-two-two billion dollars. RWE is the fifth developer to walk away from American offshore wind under this administration. The company had spent more than a billion dollars on those leases. Years of planning. Investment. Partnership with federal agencies. But RWE said there is simply no path forward to permit these projects … for the foreseeable future.

So where does the $1.22B go? Nine hundred million dollars into Louisiana LNG. Three hundred million into natural gas turbine reservations. Fifteen gas peaking projects across the country. A company that came to America to build wind farms … is now building gas plants instead.

But here is the thing about RWE. They are not leaving the wind business. They are leaving American offshore wind. Globally … RWE operates eighteen offshore wind farms. Four more under construction. And nearly seven gigawatts secured in the United Kingdom’s latest auction. America said no. The rest of the world said … come on in.

And speaking of Europe … TotalEnergies … the French oil major … just bought Shell’s entire onshore renewables business in Europe. Four gigawatts of solar and wind. Five hundred megawatts already running or under construction in Italy and the Netherlands. Three-and-a-half gigawatts more in the pipeline across Italy … the United Kingdom … and Spain. And in the same breath … TotalEnergies sold a fifty percent stake in a one-point-two gigawatt European portfolio to KKR … for an enterprise value of one-point-eight billion euros. Build it. Sell half. Keep operating it. That is the model.

Now let us fly east … to India. GE Vernova just landed a hundred-and-sixty-three megawatt wind order from American developer Enfinity Global. Forty-three turbines. Three-point-eight megawatts each. Headed for the Fatehgarh wind farm in Rajasthan. Deliveries start late this year. And those turbines will be built at GE Vernova’s factory in Pune … which can turn out fifteen hundred megawatts a year. India is pushing for five hundred gigawatts of renewable energy.

Meanwhile … up in Denmark … a Danish wind tower maker named Welcon is raising its voice. Swedish utility Vattenfall just won two offshore wind tenders in Denmark. But when asked whether they would use European-made turbines … Vattenfall would not say.

Welcon’s chief executive Jens Risvig Pedersen said … and I quote …

“It would be completely absurd not to buy European products for the two new Danish offshore wind farms. That would simply shut down the European industry.”

The Danish trade union Dansk Metal agreed. Chinese turbines … they said … should not be financed with Danish taxpayer money. Vattenfall says it has not decided yet. But the debate is on.

And finally … a milestone that happened so quietly … nobody noticed. The world just crossed three terawatts of installed solar power. It took ten years to build the first terawatt. Less than three years for the second. And not even two more years for the third. Seventy-four countries now have at least one gigawatt of solar installed. That is up from forty-two in twenty-twenty. BloombergNEF expects nine terawatts by twenty thirty-six.

But here is the catch. Without batteries … solar hits a ceiling. Places like Australia and California already have so much solar that electricity prices go negative during the day. You heard that right. They pay people to use power. The answer is battery storage. But batteries are not able to keep up with the pace of solar.

Now … if you step back from all of this … something interesting emerges. Nobody in these stories is arguing about whether wind works. Not the judge in Oregon. Not RWE. Not even the Pentagon. The debate has moved on. The question is no longer … can you build a wind farm. The question is … who gets to decide where one goes.

Think about that. A federal judge did not rule that wind turbines are safe or good or necessary. She ruled that the government cannot ignore its own laws. The science was not on trial. The process was.

RWE did not surrender its leases because offshore wind failed. It surrendered them because one government made permitting impossible … while eighteen other wind farms in its global portfolio kept spinning.

And TotalEnergies did not buy four gigawatts of European renewables out of charity. It bought them because Shell … an oil company … decided those assets no longer fit its strategy. One oil major’s exit is another’s entrance. The assets did not lose value. They changed hands.

That is the story underneath all these headlines. Wind energy has crossed a threshold that most industries never reach. It is no longer competing on technology. It is competing on governance. The turbines work. The economics work. The engineering works. What varies … country by country … is whether the rules of the road are clear enough for capital to show up.

And capital … as we saw this week … will always find the door that is open.

That is the state of the wind industry for the 10th of August … twenty twenty-six. Join us for the Uptime Wind Energy podcast tomorrow.

Judge Ends Pentagon Wind Freeze, RWE Exits US Offshore

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