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Blade Failure Alert: How ONYX Prevents Million-Dollar Disasters

ONYX Insight‘s ecoPITCH system prevents catastrophic wind turbine blade failures caused by pitch bearing issues. Forrest French and Martin McLarnon reveal how continuous monitoring and early detection can save wind farms millions.

Contact Martin McLarnon: martin.mclarnon@onyxinsight.com

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Allen Hall: ONYX Insight’s ecoPITCH monitoring system has become crucial for wind farm operators facing blade root insert failures. These failures start invisibly but can end catastrophically with blades detaching completely. This week we speak with Forrest French Senior Project Engineer, and Martin McLarnon, sales Director for North America at ONYX Insight.

Their ecoPITCH system detects dangerous movements before visible signs appear as Forest notes in the interview. By the time you can get a feeler gauge measurement, it’s probably too late. So join us to discover how data-driven monitoring is helping operators make smarter maintenance decisions preventing million dollar disasters and keeping turbines spinning safely.

Welcome to Uptime Spotlight, shining Light on Wind. Energy’s brightest innovators. This is the progress powering tomorrow.

Allen Hall: Martin and Forest. Welcome to the [00:01:00] show. Hello. How’s it going? Thanks for letting us. Yeah, we’re really interested to, to talk to you today just because there’s so many blade root issues from pitch bearings and blade bushings or inserts as they’re called sometimes, and a number of other issues. And when we talk to operators, what they tell us is, oh, we, you use ecoPITCH.

And they love that system. But I want to, I wanna back up first and talk about what are some of the operators experiencing out there in the field And ecoPITCH system was originally developed to look at pitch bearing problems and forests. What are some of those pitch bearing problems you’re seeing out in the field today?

Forrest French: Yeah, so it, it, it’s a funny story. It was originally developed for pitch bearing, uh, applications. Um, the industry as a whole started experiencing this root insert issue, so we were able to, we were kind of in a perfect position, right? It was, it was a, it was a [00:02:00] really serendipitous thing that we, we had just developed this product and we could easily pivot.

To measure both the pitch bearing and this root insert issue. Uh, the, the pitch bearing issues are admittedly the, the more difficult, uh, issue, right? To measure. Um, there’s, there’s some, some great opportunities for value and there’s also some really good challenges to come along with that. Um, pitch bearings, uh, they, they don’t rotate quickly.

Right. Uh, when, when we talk about typical CMS typical vibration monitoring, you’re looking at a very, very fast rotating, uh, shaft or bearing, et cetera, and you’re able to pick up on those frequencies as they revolve. You don’t get that with a pitch bearing. It’s a very slow moving, uh, slewing bearing. Um, so picking up.

Noise through vibration can be very difficult, uh, because again, you don’t get that frequency of that [00:03:00] rotation, so you’re left with nothing but uh, a bunch of noise. Right. And you’re hoping that that noise floor is low enough that you might capture a bit of crunching of cage material or anything like that?

Right. The alternative in what, in what we use ecoPITCH for is it’s very simple. We, we point a an inductive displacement sensor right at the pitch bearing itself. Typically the inner ring, depending on the type of turbine. And what we’re looking for is any kind of slop or displacement between the inner and outer ring.

And there’s always gonna be some, right. Uh, but, but what we’re looking for is. Is a change in the amount of, of movement between those two rings, which may indicate falling or, or other failure modes within the raceways. The challenges come along when you have failure modes that maybe, maybe don’t show themselves right through that displacement because it’s absolutely possible to, to completely lock [00:04:00] up a bearing while, while showing almost no displacement.

So there’s, there’s, there are challenges to come along with this, so, so. ecoPITCH is great for pitch bearings, but it really needs to be coupled with good visual inspections by the sites to make sure that that bearing’s not spitting out cage material right. And something that, that maybe isn’t being seen in the data.

Allen Hall: So those measurements are important.

Right? And it’s very difficult to go up there every month or two and try to take those measurements. Are there signs on the outside that everybody should be watching for? I know when we were on site a number of times. If there’s a pitch bearing problem, you typically see grease on the outside of the blade, near the root area.

Is that the, the main source of detection at the moment?

Forrest French: Yeah. And, and you know, I think, I think every operator’s gonna have a different way of looking for this stuff. It’s, it’s not there, there’s not a, uh, a very uniform strategy, I would say. Um, but really what they’re gonna be [00:05:00] looking for yeah. Is, is exactly that.

It’s gonna be grease purging out of the seals. Um, it’s gonna be the seals themselves blowing out. Right. Um, that’s, uh, cage material. Coming out of the seals is a, is obviously gonna tell you that you’ve got some, some, uh, some balls inside your bearing that are getting locked up and pulling the cage to bits, right?

And that’s what’s gonna happen when that displacement I was talking about gets severe. So you get severe displacement. It jams up a ball, but you continue to pitch. So other balls continue to move and you kind of shred that cage and it starts spitting that material out, damaging the seal. Um, so it’s, it’s a whole process.

Yeah.

Allen Hall: So if you see grease on the outside, the seal is blown. And more than likely, if you look on the ground, you’re gonna see metal shards.

Forrest French: Potentially, yeah. Depending on what kind of collars and stuff you have. Uh, but, but yeah, usually a lot of those, a lot of those shards and, and that, that metal material is gonna get captured in a lot of that grease.

Um, so really it’s just gonna turn your [00:06:00] hub into a greasy metal mess. Right. It’s, it’s still fun to be in those, those hubs. For sure. Well,

Allen Hall: let’s talk blade uh, inserts or bushings. What do you typically see if you’re walking around a farm? When a blade bushing is starting to fail, what’s the indicator from the ground?

Forrest French: From the ground? It’s difficult. Um, what, what we’ve seen typically is you’re gonna see a, uh, and, and again, this, this depends on the turbine, uh, whether it’s an electrically driven turbine or a hydraulically driven, uh, pitch bearing, sorry. Um, with the electrically driven pitch bearings, it’s a little bit easier to spot these issues.

You’ve, you’ve got. Uh, when, when the bushing starts to fail, it will basically spit out some of this, they call it dust, like a metal dust basically. And that dust will kind of make its way out onto the outside of the blade usually. So. From the Nelle, for example, you might pop your head out the hatch, do a visual inspection of the outside of the root, [00:07:00] and you might see some of that dusting heading down, down the blade.

That’s a good indicator that, that you’ve potentially got an issue. It’s, it’s not a, a, a, a sure thing at that point. Right. Um, because there’s a lot of places where metal can can make its way into the system with the hydraulically driven turbines that. Indicator gets a lot more difficult. Um, if anybody, you know, and I’m sure a lot of the folks on the call have some of these turbines, they’re a mess usually, right?

Um, if, if, if any bit of debris gets loose, it’s gonna knock off a bunch of hydraulic lines and it’s gonna make an absolute mess. And any material that’s being spit out by those bushings, it’s just gonna get. Caught up in all that hydraulic oil, and again, it’s just gonna turn into a mess and you’re not really gonna know one from the other at that point.

You’re really just left with, with uh, uh, kind of your more rudimentary ways of looking for this and some of your [00:08:00] more labor intensive ways of looking for this

Allen Hall: force. There’s a lot of ways to inspect the blade root insert. Bushing issue as the blade moves around and I, I’ve seen some of these, uh, sites where they got a technician who climbs up in there and he is got a feeler gauge of some sort.

Is that really an effective way to, to even measure that problem?

Forrest French: Yeah. The, the feeler gauge method is. Is better than nothing. Right? You’re, you’re doing something at that point. What, what we’ve found historically is that by the time you can really get a feeler gauge measurement, uh, it’s probably too late.

At that point, you, you’re seeing a significant enough gap that you can get material in there. It’s, it’s a, you’ve got a big problem on your hands. We also see paired with that, um. We see folks doing a dial indicator measurement, right? Where you’re taking sta uh, dial indicators, you’re placing them around the circumference of the blade, and that usually involves pitching the blade out, cantilever, and then you, you just rotate the blade, and that’s in that [00:09:00]static position.

You’re not actually rotating the hub. That is, is definitely better than something like a feeler gauge methodology. The, the, the, the good thing about that is you get higher resolution and you can track that over time as you use that, that methodology. The problem with both of those though, is they’re, they’re offline measurements.

I. You’re not seeing any of the loading due to the rotation of the hub, none of the arrow loads on the blades. So what you’re gonna see is if you place a continuous monitoring system, or, or even a, a, a, a portable monitoring system on this, and you rotate that turbine, you’re gonna see a significant increase in displacement value.

So you’re getting the real picture of what’s actually happening when this turbine is operating. Right? That’s gonna give you. A lot more insight into when you need to make a decision to shut this thing down.

Allen Hall: So how far off are the feeler gauge measurements compared to the ecoPITCH system?

Forrest French: It varies. Uh, it, that’s, that’s the issue with the feeler gauge is that depending on [00:10:00] which technician, on which day.

In which position, you know, how they’re feeling that day. They’ll get a different measurement every time. Um, and that’s nothing against the technicians themselves. They’re, it doesn’t matter how perfect, how perfect you do it, you’re gonna get a different measurement every time because that, that blade is shifting and moving around and it might just sit somewhere new one day when you go up to check it.

Um, but on average, I could say easily that you could see up to. A, a difference of, I mean, two, three millimeter I’ve seen before, a difference between a feeler gauge and an actual live measurement when operating the turbine. So very significant.

Allen Hall: Well, yeah. Well, what I want to talk to then is what happens if we don’t catch these, uh, these indicators early enough?

What is the downstream effect and sort of how expensive does that get

Forrest French: The final failure is, is catastrophic. Right. The final failure is that the [00:11:00] blade falls off. It, it liberates, right? That’s the, the correct term is a liberation. Um, but nobody wants to end up with a blade in on the ground. Um, and so you, you generally have a lot of signs leading up to that.

Um, that again, you, you need some type of system to measure those. Whether that’s a manual measurement, um, using feeler gauges or dial indicators, and I have my opinions on those and we will get into that. But, or, or, or a continuous monitoring system, whether that’s permanent or a portable system, uh, such as a, a sweep.

Um, but you need to be looking out for these items in some way, shape, or form. There’s, there’s a particular subset of turbines, of blade types that are, that are known to be seeing this failure more. And it’s highly likely that if you’re listening to this, you probably know whether you have those, those blades.

You’ve probably been notified one way or another. [00:12:00] Um, but if not, we can help, we can help make that call.

Martin McLarnon: Yeah. And just, just add to that, you know, there’s other, um, owners, you know, the blade liberation potentially if it strikes the tower. Could you get tower collapse as well? So that’s like obviously, uh, huge increases.

Um, and then when that happens, you know, what are the options? You know, um, you know, what damage does that do? How long does it take to get a new blade in an expedited fashion can be even more expensive. And then the whole time you’ve got, um, the turbine is offline. And depending on what time of year that happens, you may not be able to kinda get it all, all lined up, um, for several months.

Um, so, so yeah, definitely. It’s, it’s extremely, we’d say high risk. So the, the cost impacts are, are, are really big.

Joel Saxum: I’ve, I’ve heard of, uh, touching the insurance world, right? Like farms where, and this is where the ecoPITCH system comes into play.

Wind farms that have been shut down and they haven’t been turned back on for months, entire wind farms because they don’t know how to monitor for this, or they don’t know if it’s safe to go back on. Once [00:13:00] they’ve discovered a problem, they don’t know what that, um, you know, what is our safety margin here?

What. Can we play with, how can we get this thing back running? So you guys as eco with the ecoPITCH system, have walked into that, right? You’ve been able to get these things up and running. How does that work? How does that process work with you guys?

Forrest French: So, so a situation like that, and we’ve seen this, right?

Uh, customer has a blade liberate they shut down their entire fleet because to your point, they don’t know. They don’t know, right? They don’t know what’s out there. Now, what, what other insidious failures are just waiting for them. So. What we can provide in that case is, is our, our ecoPITCH system. We have a portable.

Portion or a portable version of this where we go up tower, it’s a real quick and dirty type thing, right? We’re using magnets and Velcro, whatever we can right to crudely get this stuff into the turbine safely. Obviously it’s not going anywhere, um, but whatever it takes to quickly [00:14:00] get this system installed, what we’ll do is we’ll run the turbine for about 10 minutes, right?

We’re gonna. Take our measurements, we’re gonna get outta there, we’re gonna yank our equipment out, and we’re gonna move on to the next turbine. Generally speaking, with that system, and this depends on the turbine, you’re looking at about two turbines per day. Certain certain blade types, we have to get in the blade itself.

That can push us back to, you know, one turbine per day for confined space reasons and things like that. Um, but what that does is it provides you with. Your full population. Now you know what every blade looks like compared to the rest of the population. And what we’re doing with that data is we’re, again, we’re taking all these 10 minute data samples and we’re just saying, Hey, these, this subset of turbines needs further analysis, right?

You need to be watching these. The rest of these though are baseline. They’re all right where we expect them to be. They’re all [00:15:00] the same. The operator can quickly just go and fire those turbines back up and get back to business.

Allen Hall: And what does that data look like for us? Is it just a, a measurement or? Do you see the movement of the root and the, the pitch bearing as the turbine spins?

What, what is that data?

Forrest French: The data is, is really rudimentary. It’s very, it’s very cool and, and there’s a lot of information that you can take away from it, but at the end of the day, it’s just a sine wave. And I’m sure we’ll, we’ll provide some, some examples of that that you guys can toss up on the screen.

Um, but really what you’re seeing, and generally in a simple system, we’re gonna put a sensor up near the leading edge. Near the trailing edge, right? And if you put those two, uh, sign waves on a graph, what you’ll typically see is they’re, they’re out of phase by about 90 degrees. That’s expected as the turbine is rotating.

One side, you know, one side of the blade’s gonna go into compression, one’s gonna go into detention, and then as it swings around, it’s gonna reverse, right? So you get that 90 degree phase [00:16:00] where it starts to get fun is, uh, or fun, fun for me as the engineer looking at the data. Maybe not fun for the, the person who owns a turbine, but, uh, where it starts to get interesting is when these failures get.

Very severe. We’ve seen that that phasing actually start to line up. And what that means to me is that the blade is no longer wobbling. It’s literally pulling away all at one time and dropping back down all at once, right? So you have the entire blade system plunking up and then falling back on the bearing.

So at that point, that means that likely you’ve, you’ve lost. Enough bushings around the circumference of that blade that the entire blade is moving at the same time rather than flexing in and out. That’s a little more rare, but it’s just an example of some of the cool, uh, bits of information that we can take away from this

Allen Hall: for us, when you see these kinds of large measurements, uh, displacement happening [00:17:00] as the hub spins, putting a permanent system in, I think makes sense because you want to be able to project.

Ideally where this growth is or if it starts to vary wildly uh, or grow rapidly, you wanna be able to understand how soon to shut the turbine off. Explain to me what the logic is that goes into that, because there’s a lot of engineering that looks at that data.

Forrest French: Yeah, and this is, this is the key difference between something like a portable system that we talked about where you go up, you take 10 minutes of data and you yank it out.

The key difference between that and a continuous monitoring and a permanent system. The portable system is gonna tell you on this day at this time, what was your displacement? And that’s great information. You can absolutely action that information, but what you’re lacking is the full story, right? What, okay, it was here today, what is it tomorrow?

What is it? The next day? I’ve seen examples where, uh, I’ve put a permanent system in place and the [00:18:00] displacement value is, we’ll call it elevated. It’s maybe not in like emergency status, but it’s elevated. It stayed there. For as long as we’ve monitored this turbine, it stayed. What that means is that had you just gone and done dial indicator measurements or even a portable suite, you might end up thinking, we need to, we need to action this.

We need to replace this blade. However, with a permanent system, you’re now armed with that knowledge to say, no, let’s monitor. Let’s keep watching it and wait until it does actually grow. And that’s the full picture, right? If I go and put a system in place, and I’m seeing that gross pattern, and, and Martin used the term peak to peak earlier, and what that’s referring to is that sine wave that we’re talking about.

The distance that the target is moving away from the sensor, the top minus the bottom of that waveform, gives you your full displacement, your peak to peak, as that peak to peak grows. What we generally see is a, an an [00:19:00]exponential growth. Once it starts to go, once you get a, a significant number of these bushings that start to fail, the rest of the bushings that are already prone to failure continue to fail, and then you have a cascading effect where you just start to release.

Um, so being able to watch for that and being able to make a risk-based decision with that data. Is crucial.

Joel Saxum: So for, with that being said, when an, when you guys are dealing with an operator, do you have a set metric or is it case by case? When you know like, hey, this thing is starting to unzip itself. What does that look like?

What’s the time look like? Do they have an hour? Do they have a month? What does, what are they thinking?

Forrest French: The timing can change depending on the, the type of blade, the environment right. That it’s in, how it was installed. Um. How many, how many blade bolts have broken over time, right? That, that time can change significantly.

On average, I would say that we go [00:20:00] from making a call to notify a customer that you have an issue that is starting to reveal itself to, we probably need to consider shutting this thing down is usually on the order of two months, on average, probably. Um, so. Not, we’re not talking days. Right. It, it, it can be though.

Allen Hall: Maybe give us a picture of what the system looks like when it’s installed in, at the base of Blade or in the hub.

Well,

Forrest French: I’ll, I’ll, I’ll, I’ll start with the root insert. Um, it’s the one that’s a little more interesting as far as the installation goes, but. Typically what we’re gonna have is we’re gonna have our CMS boxes, right? There’s two of them. Um, they’re about, yeah, I mean about a foot, foot by foot, maybe. Um, you’ve got two of those guys depending on the turbine.

And this is the fun of my job as, as the ecoPITCH application lead. Every turbine I get to go up and make a custom installation design, right? We have to find somewhere to put these boxes, and, and we’ve talked about it. These, these turbines, these hubs [00:21:00] are not designed to be, uh, retrofit friendly, right?

There’s nowhere to put this stuff. They don’t, they don’t leave bolt holes for you to put things. So we have to get really creative in order to design a robust system that’s gonna survive in this environment. But I digress. Generally you’re gonna have your two CMS boxes mounted somewhere in the hub, um, on a, a mounting plate of some kind.

Uh, and then from there, at most you’re gonna have about nine displacement sensors. So three sensors in each blade. Those sensors are wired. Uh, so what, we’ll, what we’ll typically do is I’ll have, uh, for example, a, an anchor of some kind. Dead center or in the center of rotation inside the blade itself. And I’ll typically have a, a.

Some kind of, uh, I’ve used very fancy, uh, uh, industry grade bungee cable, basically. Uh, or, or [00:22:00] similar, uh, metal, cable, whatever it may be. Um, it’s something with some stretch and some give because we have a rotating component, but the cables will then drop down onto that anchor. They’ll come up that, that fancy bungee cord right from there.

They’ll be routed along existing cable lines to the boxes themselves. Um, the sensors are mounted. It’s a pretty simple thing. The sensors are mounted using a combination typically of a, of a, of a double-sided tape and a liquid epoxy. The double-sided tape is there for installation efficiency, uh, because it’s very difficult to install a liquid epoxy overhead.

But we’ve never had any, any, any, any issues with that design so far.

Joel Saxum: And I’m gonna throw one more at you here because this is something that Alan and I run into almost everywhere. We, we end up when we’re talking I, iot or anything else. Cybersecurity. Right? Because at the end of the day, this is the conversation we have.

Oh, you can solve a problem. Great. I’m gonna pass it. Oh wait, cybersecurity. We gotta make sure this is, [00:23:00] that we can get these things actually installed in our turbine. So how does, uh, ONYX Insight handle that with this system?

Forrest French: Sure. So I, I think a couple key things, right. First and foremost, I think a lot of people jump for joy when we tell them that our system is run off of a 4G router.

It does not connect to the turbine operating, so it does not connect to the turbine at all. Right. It runs fully on its own. Um, there are, you know, there are still, those questions absolutely come up still. Right. Even though it’s, it’s just taking data from our system. It’s not getting any kind of operating data from the turbine itself.

We still get that question right, and I think it’s perfectly fair. However, um, we’ve had multiple success stories up to this point, right? We’ve, we’ve, we’ve, uh, we’ve been able to work through those. We have a dedicated IT team. We’re up to date on cybersecurity, uh, certifications and those items. I’m not an IT guy, but we have a whole IT group that takes care of this, right?

So when those [00:24:00] concerns do come up. We’re locked and loaded. We’re ready to get them chatting with the people who they need to chat to, to make sure that whatever cybersecurity questionnaires or, uh, you know, confirmations need to be done, it can be done and it, and it does get done. So that, that’s, that’s, I think, I think the best news is just, it’s, it’s fully standalone, right?

There’s no ethernet connection to the tower itself.

Allen Hall: All right, so that sounds really simple and easy to do, and you can do it in a temporary fashion and get yourself some data across the whole fleet. Or if in some cases when you triage these, you’ll want to keep the system in there longer term to help you understand when repairs need to take place.

And this is where the money comes in because it’s all at the end of the day, is about using your resources wisely as an operations. And your o and m budget is limited and is. Tends to get limited more and more every year. So you want to be spending the money wisely, which is what ecoPITCH System does.

How does, how do you project then, when you have that data [00:25:00] and you’re starting to get that streaming coming in, you’re seeing the, the blade movement play out. How are you spending your budgets there? How do you appropriate the right amount of funds for the right size of problem?

Martin McLarnon: Yeah, so we’ve got, um, um, a good case study with a customer who had installed ecoPitch permanent, uh, for insert issue. And they had quite a lot of historical issues with this, um, and, and really trying to manage this, this problem. Um, and like how do they keep operating the turbine, uh, wind farm safely while, while these, uh, issues are ongoing? So really legal pitch was really unique and enable enabling them to do that.

They get this peak to peak measurement that, that we’re measuring, you know, all the time. And seeing how that, um, changes over time. So gives ’em the benefit of an early stage indicator. And as far said, it’s a, it’s a direct measurement and it’s, um, you know, through the actual operation of the, the turbine rotation.

Like some of these other, you know, [00:26:00] one off measurements are very, you know, it’s whenever the, the, the blades are static, it doesn’t show that true, um, garbing throughout the whole rotation. So. Um, that we were able to see that whole progress from really early stage. So things that we talked about, getting a new blade or looking at some engineering, uh, solutions, gives them time to plan that out, but also in the right way so they can wait until it gets to a point, um, where they’re, um, you know, saying that this needs to be switched off.

We’re not comfortable anymore with the level of the gabbing. Um, and even to that point when even the, the blade itself is, is switched off, turbine, switched off, there could be still a chance of slippage and the blade continuing to, to fall off. They need to know that as well, for safety reasons. So until that blade gets replaced or repaired, they need to have really good visibility on, on what that condition is.

But effectively, you know, across a large wind farm, it really helps them manage things rather than, uh, you know, switching everything off when just, you know, [00:27:00] until they replace all the blades, which isn’t really. Realistically an option anyway. So they have to really help some manage that. Loose budgets, excuse me.

And uh, yeah, supply chain, um, lead times, things like that. You have, that all has to be managed. Um. So it’s been a really good success story.

Allen Hall: And all this is backed by all the engineers and scientists that are at ONYX Insight.

And Martin, maybe you can provide a little summary of that because if you haven’t worked with ONYX Insight, you may not realize the power and the capability that exists within in that building.

Martin McLarnon: Yeah, yeah. And it’s great, you know, here in Forest talk through the, uh. The application for, for ecoPITCH. So, you know, obviously, you know, we’ve got a really talented bunch of engineers that can, you know, really explain, uh, the issues and under, you know, we really are understanding, um, the problems customers have, which is unique, uh, depending on the turbine type, um, or, or the specific issue.

And, and that’s really how, you know, ONYX is, um, business has really grown over the [00:28:00] years. Is that continuous, um, collaboration with customers. What sorts of issues are coming up like for said. This root insert issue has just kind of emerged in the last couple of years. It wasn’t something people were, uh, necessarily expecting.

And, um, we were always trying to drive to have those, those discussions. So for us, we, um, you know, background is in, uh, a lot of me, mechanical engineering and gearbox design was our original, uh, how we started out. But then getting into drive, train, uh, monitoring, vibration monitoring, CMS hardware, um, um, with, you know.

Principal engineers with decades of experience, like, you know, global team, uh, different data analysts as well. So we, um, yeah, really have expanded that from drive chain, uh, skid analytics, um, foundation monitoring, uh, pitch bearing, um, and, uh, and this route insert blade monitoring as well. So, um, yeah, we really, whenever customers have have those issues, we like to [00:29:00]discuss it, figure out what, what the potential solutions are, and.

Uh, it could be a new, a new product for us. Um. E eventually, if that’s, if that’s something we can, uh, kinda get a good solution for or release. Provide advice to the customer.

Allen Hall: Yeah. If you have blade root insert issues or pitch bearing issues, you do not wanna mess with them. Or even blade bolts because blade liberation is so expensive.

And when you have those issues, you want to go to accompany. Like ONYX Insight because they have the expertise. They’ve been around a long time. They’re a part of some OEMs equipment and they understand the variations between all those different blade models and turbine types. That’s where you wanna start because you’re gonna save your company.

I. Millions of dollars in losses in downtime. And Martin, how do people who are not familiar with On Insight get ahold of you and talk about ecoPITCH to see how they can get it installed in their turbines?

Martin McLarnon: Yeah, I, um, we confirm my, uh, email address in the chat. Um, I’m a [00:30:00] cover the North American region, so hobby to, um, you know, get, get involved in that discussion.

And we’ve got global, uh, commercial folks, so I will get. Get the, you connected to them and I’d love to have a conversation.

Allen Hall: And you can always visit ONYX Insight ONYXinsight.com. Great website, and you can learn more about ecoPITCH on that site. There’s a good PDF download there if you wanna learn more.

And yes, reach out to ONYX Insight. Reach out to to Martin, reach out to, for. Get your questions answered now, because as the season progresses, it’s only gonna be more expensive and at the right time to do this kind of inspection and data acquisition is now so. Martin and Forrest, thank you so much for appearing on the show.

I really appreciate all of the information. Absolutely.

Forrest French: Thanks

Allen Hall: for having us.

Martin McLarnon: Thanks Al Joel. Appreciate [00:31:00] it.

https://weatherguardwind.com/onyx-insight-ecopitch-blade-root/

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Pardalote Studies Australian Blade Erosion and Heat Fatigue

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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 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!

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.

Pardalote Studies Australian Blade Erosion and Heat Fatigue

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Renewable Energy

Artificial Stupidity?

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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?

Artificial Stupidity?

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Renewable Energy

No Such Thing as a “Dumb Question”

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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.

You might have thought that Americans wouldn’t have voted for their nation to become Russia or North Korea.

You would have been wrong.

No Such Thing as a “Dumb Question”

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