Published

2 years ago

March 10, 2024

Alice Rush

The Whirring Rise of Wind: Central America’s Evolving Energy Landscape

Central America, a region known for its lush rainforests and volcanic peaks, is witnessing a transformation in its energy sector.

Once heavily reliant on hydropower and then fossil fuels, the region is increasingly embracing wind energy as a clean and sustainable alternative. This shift towards wind power has unfolded in a fascinating journey, marked by distinct phases.

In the first chapter, stretching back before the mid-1990s, hydropower reigned supreme. Abundant rivers provided a dependable source of electricity. However, this dominance faced challenges with growing concerns about environmental sustainability and the vulnerability of hydropower to unpredictable droughts.

The mid-1990s ushered in the second phase, where fossil fuels like oil emerged as a replacement for the limitations of hydropower. This reliance, however, exposed Central American nations to the volatility of oil prices. The need for a more diversified and secure energy source became increasingly clear.

The turning point arrived in the mid-2000s. Pioneering countries like Costa Rica, with the first commercial-scale wind farm in Latin America built in 1996, led the charge. Wind power’s rise was fueled by several factors: the allure of renewables amidst fluctuating oil prices, government policies promoting clean energy portfolios, and the presence of strong wind resources in specific regions across Central America. This marked the beginning of the third phase, where wind energy has become a well-established renewable source in the region’s energy mix.

Hystory of Wind Energy Development in Central America

Central America’s journey with wind energy can be summarized in three key phases:

1. Hydropower Dominance (Pre-Mid 1990s): Historically, hydropower reigned supreme in Central America. Rivers provided a reliable source of electricity, but droughts and environmental concerns later challenged this dominance.

2. Fossil Fuels Take Over (Mid 1990s – Mid 2000s): As hydropower faced limitations, fossil fuels like oil stepped in to fill the energy gap. This increased dependence on volatile oil prices exposed the need for diversification.

3. Rise of Renewables, Including Wind (Mid 2000s – Present): The mid-2000s marked a turning point. Countries like Costa Rica, Nicaragua, and Honduras began embracing wind power to reduce reliance on fossil fuels and enhance energy security.

Here are some additional details about this development:

Pioneering Steps: Costa Rica holds the distinction of having the first commercial-scale wind farm in Latin America, built in 1996.
Growth and Challenges: Wind energy capacity has grown steadily since then, but Central America lags behind some other Latin American countries in total installed capacity.
Factors for Growth: Several factors fueled wind energy’s rise:
- Fluctuations in oil prices made renewables more attractive.
- Government policies promoting renewable energy portfolios provided a push.
- Central America boasts strong wind resources in specific regions.

Current Status:

While hydropower remains a significant player, wind energy is a well-established renewable source in the region. Countries like Costa Rica and Panama boast a significant share of wind power in their energy mix.

Central America has the potential to further develop its wind energy sector. Continued investment, improved infrastructure, and addressing concerns from local communities will be crucial for its future growth.

Central America Wind Energy Landscape: Statistic Data

Here’s a breakdown of some key statistics on Central America’s wind energy landscape:

Installed Capacity:

Data can vary depending on the source, but as of 2022, estimates suggest Central America has around 4-5 Gigawatts (GW) of total installed wind energy capacity.
Nicaragua leads the region with over 2 GW, followed by Honduras with around 1.5 GW.
Guatemala, Panama, and Costa Rica also have operational wind farms, but with smaller capacities.

Energy Generation:

Wind energy contributes a significant portion of electricity generation in some Central American countries.
In Nicaragua, wind power can account for over 30% of national electricity generation at peak times.
Honduras and Guatemala also see a growing contribution from wind, although the percentage might be lower than Nicaragua.

Growth Potential:

Central America has the potential to significantly increase its wind energy capacity. Studies suggest potential for up to 20 GW of installable wind resources across the region.
Continued policy support, grid modernization, and technological advancements can unlock this potential and further diversify the energy mix.

Central America Wind Energy Landscape: Benefits and Advantages

Wind energy offers a multitude of benefits and advantages for Central America, contributing to both environmental and economic well-being. Here’s a breakdown of some key points:

Environmental Benefits:

Reduced Greenhouse Gas Emissions: Wind energy is a clean and renewable source of power. Unlike fossil fuels, wind turbines do not produce greenhouse gasses during operation, contributing to combating climate change.
Improved Air Quality: Transitioning to wind energy reduces reliance on fossil fuels, which can significantly improve air quality by lowering emissions of pollutants like sulfur oxides and nitrogen oxides.
Conservation of Water Resources: Wind energy production doesn’t require large amounts of water unlike some traditional energy sources, minimizing pressure on freshwater resources.

Economic Benefits:

Reduced Reliance on Fossil Fuel Imports: Central America relies heavily on imported fossil fuels, making them vulnerable to price fluctuations and supply disruptions. Wind energy offers a domestic and stable source of energy, reducing dependence on imports and potentially lowering energy costs in the long run.
Job Creation: The wind energy sector creates jobs in manufacturing, construction, operation, and maintenance of wind farms. This can contribute to economic growth and development in the region.
Rural Development: Wind farms are often located in rural areas, bringing investment and economic opportunities to these communities. Landowners can benefit from lease agreements with wind farm developers, generating additional income.

Additional Advantages:

Energy Security: Wind energy diversification strengthens energy security by reducing dependence on a single fuel source.
Sustainable Development: Wind energy aligns with the principles of sustainable development by providing clean energy while minimizing environmental impact.

Wind energy offers a win-win situation for Central America. It promotes environmental health, fosters economic growth, and strengthens energy security, paving the way for a more sustainable future.

Central America Wind Energy: Policy and Regulation

Central America boasts excellent wind resources, particularly in Nicaragua, Honduras, and Guatemala. To harness this potential, governments in the region have implemented various policies and regulations:

Favorable Policies:

Renewable Energy Targets: Most Central American countries have established ambitious renewable energy targets, with wind playing a significant role.
Feed-in tariffs and Auctions: Many countries use feed-in tariffs or auctions to guarantee prices for electricity generated from wind power, making it financially attractive for developers.
Fiscal Incentives: Tax breaks and exemptions on import duties for wind equipment can reduce project costs and encourage investment.

Regional Integration:

The Central American Electricity Market (MER): This supranational body facilitates regional power trade, allowing wind-rich countries to export surplus electricity to their neighbors.

Challenges Remain:

Streamlining Regulations: Complex and lengthy permitting processes can slow down wind project development.
Grid Modernization: Upgrading transmission infrastructure is crucial to effectively integrate wind energy into the regional grid and manage fluctuations.
Social and Environmental Impact: Careful environmental impact assessments and community engagement are needed to address concerns about land use, wildlife, and noise pollution from wind farms.

Resources for Further Reading:

**Renewable Energy Roadmap for Central America: Towards a Regional Energy Transition (International Renewable Energy Agency: [IRENA]”: This report by IRENA outlines a pathway for Central America to achieve a significant increase in wind energy and other renewables.
Renewable Energy Sector in Central America – Trade – European Commission: This European Commission document provides an overview of the renewable energy sector in Central America, including wind energy policies and challenges.

Central America Wind Energy Landscape: Infrastructure

Wind energy relies on a network of infrastructure to function effectively. Here’s a look at the key components in Central America:

Wind Farms:

These are the heart of wind energy production, consisting of numerous wind turbines spaced strategically across a land area with strong and consistent winds.
Central America has wind farms of varying sizes, with Nicaragua and Honduras boasting some of the largest.

Wind Turbines:

These towering structures convert wind energy into electricity. Modern turbines have large blades that capture wind and rotate a shaft connected to a generator.
Technological advancements have led to taller turbines with larger blade spans, allowing them to capture more wind and generate more electricity.

Transmission Lines:

High voltage transmission lines are crucial for carrying the electricity generated by wind farms over long distances to population centers and substations.
Upgrading and expanding the regional transmission grid is essential to integrate wind energy effectively and avoid bottlenecks.

Substations:

These electrical substations act as control centers, transforming the high voltage electricity from wind farms to lower voltage levels suitable for distribution to homes and businesses.
Modern substations can also integrate energy storage solutions to help manage fluctuations inherent in wind power generation.

Supporting Infrastructure:

Access roads, maintenance facilities, and communication networks are also necessary to ensure the smooth operation and upkeep of wind farms and their associated infrastructure.

Challenges and Opportunities:

Grid Modernization: Central America’s existing transmission grid faces limitations in handling the variable nature of wind energy. Upgrading the grid requires significant investment but is crucial for maximizing wind energy potential.
Interconnectivity: Strengthening regional electricity interconnection allows for smoother energy exchange between countries, enabling wind-rich nations to export surplus power to their neighbors.
Smart Grid Technologies: Implementing smart grid technologies can enhance grid management and improve the integration of wind power by dynamically adjusting power flow based on real-time wind conditions and electricity demand.

By addressing these challenges and leveraging opportunities, Central America can further strengthen its wind energy infrastructure and unlock its vast potential for clean and sustainable energy generation.

Central America Wind Energy Landscape: Wind Farm Projects

Here are some of the significant wind farm projects operational or under construction in the region:

Cerro de Hula Wind Farm, Honduras: Located southwest of Tegucigalpa, Honduras, this wind farm holds the title of the largest in Central America with a capacity of 102.5 MW. It consists of 51 wind turbines and supplies clean energy to thousands of homes.
Eolo Nixcoyol Wind Farm, Nicaragua: Situated in Rivas, Nicaragua, Eolo Nixcoyol boasts a capacity of 64 MW, significantly contributing to the country’s wind energy production and its goal of becoming a leader in renewable energy.
San Buenaventura Wind Farm, Panama: Located in the Chiriquí province of Panama, San Buenaventura has a capacity of 100 MW, contributing to Panama’s transition towards a cleaner energy mix.
Planta Eólica Punta Cana, Dominican Republic: While geographically not part of Central America, the Dominican Republic is another major player in Caribbean wind energy. Punta Cana is the largest wind farm in the country with a capacity of 80 MW.
Santa Ana Wind Farm, El Salvador: El Salvador’s wind energy sector is relatively new but growing. Santa Ana, with a capacity of 50 MW, is one of the largest operational wind farms in the country.
Jäkälä Wind Farm, Costa Rica: A leader in Central American renewable energy, Costa Rica has several notable wind farms. Jäkälä, located in Guanacaste province, has a capacity of 55 MW and contributes to the country’s impressive reliance on clean energy sources.
Miramar Wind Farm, Nicaragua: Another significant wind project in Nicaragua, Miramar boasts a capacity of 49.5 MW, exemplifying the country’s commitment to wind energy and diversification of its energy mix.
El Coyol Wind Farm, Costa Rica: Further contributing to Costa Rica’s clean energy production, El Coyol wind farm has a capacity of 45.5 MW.
Agua Caliente Wind Farm, Nicaragua: Located in Rivas, Nicaragua, Agua Caliente contributes 35.5 MW to the national grid.
Xoel Schacher Wind Farm, Nicaragua: Another wind farm in Rivas, Nicaragua, Xoel Schacher has a capacity of 30 MW and helps power Nicaraguan homes and businesses with clean energy.

This list is not exhaustive, and there are many other wind farm projects under development or recently completed across Central America. As the region strives for cleaner energy solutions, wind power is certain to play an increasingly vital role.

Central America Wind Farm Projects: a Table overview

Country	Wind Farm Project	Capacity (MW)
Honduras	Cerro de Hula	102.5
Nicaragua	Eolo Nixcoyol	64
Panama	San Buenaventura	100
Dominican Republic*	Planta Eólica Punta Cana	80
El Salvador	Santa Ana	50
Costa Rica	Jäkälä	55
Nicaragua	Miramar	49.5
Costa Rica	El Coyol	45.5
Nicaragua	Agua Caliente	35.5
Nicaragua	Xoel Schacher	30

Dominican Republic is geographically not part of Central America but included for reference.

Central America Wind Energy Landscape: The Technology

Central America has good potential for wind energy, and it’s playing an increasingly important role in the region’s transition to renewable energy sources. Here’s a breakdown of the wind energy technology being used in Central America:

Dominant Technology:

Horizontal-axis wind turbines (HAWTs): These are the most common type used worldwide, and they are also the dominant technology in Central America. HAWTs have a long, horizontal shaft with blades that rotate perpendicular to the wind direction. The wind spins the blades, which in turn convert the kinetic energy into electricity through a generator.

Trends and Advancements:

Larger turbines: As wind technology advances, turbines are becoming larger and more powerful. This allows for capturing more wind energy and generating more electricity per turbine.
Improved efficiency: Advancements in blade design and materials are leading to more efficient turbines that can capture more energy from weaker winds.

Considerations for Central America:

Site selection: Careful selection of wind farm locations is crucial to ensure consistent and strong winds. This often involves analyzing wind resource maps and conducting on-site wind measurements.
Grid integration: Integrating wind energy into the existing power grid is essential. Sometimes, grid upgrades might be necessary to handle the variable nature of wind power.

Central America is utilizing well-established wind energy technology with ongoing advancements to maximize efficiency and power generation from this renewable resource.

Central America Wind Energy Landscape: Private Sector Contribution

The private sector plays a vital role in driving the growth of wind energy in Central America. Here’s how:

Investment and Project Development:

Financing: Private companies invest significant capital in developing, constructing, and operating wind farms. This helps to reduce reliance on public funding for renewable energy projects.
Expertise: Private companies bring expertise in wind turbine technology, project management, and construction. This ensures efficient development and operation of wind farms.

Market Participation:

Independent Power Producers (IPPs): Many wind farms in Central America are built and operated by IPPs. These companies sell electricity to utilities or directly to large consumers through power purchase agreements (PPAs). This creates competition in the energy market, potentially leading to lower electricity prices.
Operation and Maintenance (O&M): Private companies often provide O&M services for wind farms, ensuring the smooth operation and performance of the turbines.

Policy Advocacy:

Collaboration with Government: Private companies can collaborate with governments to develop supportive policies and regulations for wind energy development. This can create a more attractive investment environment for renewable energy projects.

Challenges and Opportunities:

Streamlining Permits: Long and bureaucratic permitting processes can hinder project development. Private companies can advocate for streamlining these processes.
Attracting Investment: Creating a stable regulatory framework and providing attractive financial incentives can encourage further private sector investment in wind energy.

The private sector is a key driver of wind energy development in Central America. By investing in projects, providing expertise, and advocating for supportive policies, private companies are helping to expand renewable energy and transition the region towards a more sustainable future.

Central America Wind Energy Landscape: Key Player Company

While there isn’t a single dominant company solely focused on wind energy in Central America, several key players contribute to the industry’s growth. Here’s a breakdown of some important participants:

Independent Power Producers (IPPs):

These are private companies that invest in, develop, and operate wind farms. They sell electricity to utilities or large consumers through power purchase agreements (PPAs). Examples of IPPs active in Central America include:
- Corporación Multi Inversiones (CMI) Energía: A prominent player with wind farms in Guatemala, Costa Rica, and Panama. They issued the largest green bond for a renewable energy company in Central America and the Caribbean [CMI Energia Press Release].
There are many other IPPs involved in Central American wind energy, making the market diverse.

Turbine Manufacturers:

These companies manufacture and supply wind turbines used in wind farms. Major global players like:
- Vestas Wind Systems A/S
- Siemens Gamesa Renewable Energy SA
- They don’t directly operate wind farms but provide the critical technology.

Utilities:

Established utility companies in Central America might also invest in or manage wind farms alongside their traditional operations.

The Central American wind energy landscape is driven by a combination of IPPs bringing investment and expertise, global turbine manufacturers supplying the technology, and potentially existing utilities participating in the market. It’s a collaborative effort where different players contribute their strengths.

Central America Wind Energy Landscape: Financial Support

Central America’s wind energy sector thrives due to a combination of funding sources, including public and private initiatives. Here’s a breakdown of the key financial support mechanisms:

Public Funding:

International Financial Institutions: Multilateral organizations like the World Bank, Inter-American Development Bank (IDB), and the Central American Bank for Economic Integration (BCIE) provide loans and grants to support renewable energy projects, including wind farms.
National Governments: Some Central American governments offer financial incentives for wind energy development, such as tax breaks, feed-in tariffs (guaranteed prices for electricity produced from renewable sources), and concessionary financing.

Private Investment:

Independent Power Producers (IPPs): As mentioned earlier, IPPs are a major driving force. They raise capital from private equity firms, banks, and institutional investors to finance wind farm projects.
Green Bonds: Issuing green bonds allows companies to raise funds specifically designated for renewable energy projects. This is becoming an increasingly popular option in Central America.

Additional Considerations:

Risk Mitigation Instruments: Guarantees and insurance products can help mitigate risks associated with wind energy projects, making them more attractive to investors.
Carbon Markets: If properly established, carbon markets could create additional revenue streams for wind farm developers by generating tradable carbon credits.

The financial landscape for Central American wind energy is evolving. International support plays a role in getting projects off the ground, while private sector investment is crucial for sustained growth. Innovative financial tools like green bonds and risk mitigation instruments are also contributing to making wind energy a more attractive investment.

Central America Wind Energy Landscape: Enviromental Impact

Central America’s Wind Energy: A Balancing Act

Central America boasts abundant wind resources, making it a prime location for wind farms. While wind energy offers a clean alternative to fossil fuels, it’s not without environmental considerations. Here’s a breakdown of both sides of the coin:

Benefits:

Reduced Greenhouse Gas Emissions: Wind turbines don’t burn fossil fuels, resulting in significant cuts to greenhouse gasses and air pollution compared to traditional power plants. This combats climate change. (reference: [IRENA Latin America Market Analysis])
Renewable Resource: Wind is a constantly replenished resource, unlike fossil fuels. This ensures a sustainable energy source for the future.

Challenges:

Impact on Wildlife: Spinning turbine blades can pose a threat to birds and bats, causing collisions and fatalities. Careful planning and mitigation strategies are crucial. (reference: [Unjust Transition: Environmental Justice Issues])
Habitat Disruption: Constructing wind farms can disrupt natural habitats, affecting local flora and fauna. Minimizing land use and choosing appropriate locations are key.
Visual and Noise Pollution: Large wind turbines can alter the landscape and generate noise, potentially impacting nearby communities.
Social Impact: Wind farm development might lead to land-use conflicts and displacement of local communities. Open communication and community engagement are essential.

Moving Forward:

Central American countries can harness wind energy’s potential while minimizing environmental drawbacks by:

Strategic Siting: Conducting thorough environmental impact assessments to identify locations with minimal wildlife and habitat impact.
Technological Advancements: Utilizing bird-friendly turbines and innovative deterrents to minimize wildlife collisions.
Community Engagement: Involving local communities throughout the planning process, addressing concerns, and ensuring fair compensation for any land use.

By carefully considering these environmental factors, Central America can develop a robust wind energy sector that contributes to a cleaner future without compromising ecological well-being.

Conclusion for Central America Wind Energy Landscape

Central America boasts potential for wind energy, with several countries like Costa Rica and Honduras already generating power through wind farms. While progress has been made, some nations still rely heavily on fossil fuels. This highlights the opportunity for further development in the region to tap into this clean and abundant energy source.

Central America has good potential for wind energy, with some countries already leading the way.

Here’s a summary:

Growth potential: The region is seeing increasing wind power capacity, contributing to the global renewable energy landscape.
Leaders: Costa Rica, Honduras, and Nicaragua have the most established wind farm operations.
Room for improvement: While some rely on renewables like geothermal, other countries depend more on fossil fuels for electricity generation.

Central America is on the path to harnessing more wind energy, but there’s opportunity for further development.

https://www.exaputra.com/2024/03/central-america-wind-energy-landscape.html

Related Topics:Development renewable energy Sustainability

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Renewable Energy

CNC Onsite Cuts Repair Costs With Uptower Machining

Published

5 hours ago

May 7, 2026

Alice Rush

Weather Guard Lightning Tech

CNC Onsite Cuts Repair Costs With Uptower Machining

Søren Kellenberger, CEO of CNC Onsite, joins to discuss uptower yaw gear repairs, flat tower flanges, and replacing 1,000 blade root bushings across 26 turbines.

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!

Allen Hall 2025: Soren, welcome back to the podcast.

Søren Kellenberger: Thank you, Allen, and, uh, nice doing it, uh, face-to-face- Yes, it’s great … and not as a team, uh, call. Right. That’s

Allen Hall 2025: true. Yeah. You’ve been doing a good bit of traveling, and you’re the new head of CNC Onsite.

Søren Kellenberger: I am, yes.

Allen Hall 2025: So congratulations on that.

Søren Kellenberger: Thank you very much.

Allen Hall 2025: And all the exciting new things that CNC Onsite [00:01:00] is doing, plus all the things you have developed and are now out in the field implementing, the, the list goes on and on and on.

I’m alwa- every time I talk to you, “Oh, we got a new-” Yeah … “machine to do something uptower.” So it’s all uptower, which is the, the beauty of CNC Onsite. You’re thinking about the operator and the cost to pull the blades off and do lifting the cell off and all those things. If we can do it uptower, we can save 30, 40, 50% of the cost of a repair.

Søren Kellenberger: Yeah.

Allen Hall 2025: That’s where CNC Onsite is just really killing it. You guys are doing great. Thank

Søren Kellenberger: you. Of course, we like what we do, but, uh, thank you.

Allen Hall 2025: Yeah. Yeah. Yeah, yeah. No, it’s good, it’s good. And, and so w- let’s talk about the things that I know about, and we’ll start there, and then we’ll go to all the new things you’re doing.

So the one that I see a lot of operators asking about is yaw tooth. Yeah.

Søren Kellenberger: Uh,

Allen Hall 2025: deformations, broken teeth on the yaw gear. That’s a big problem. And when I talk to [00:02:00] technicians, and I have them texting me about this, like, “Oh, well, I just weld on the gear back on, weld the tooth back on.” That’s a short-term solution.

That’s not gonna be long-term. The long-term solution is the CNC Onsite. Can you explain what you do to permanently fix these yaw gear problems?

Søren Kellenberger: Yeah. So what we do is actually we start by getting information about the, uh, original yaw ring, so the dimension of the teeth, and we get some load data. And, uh, then we start designing a replacement segment.

Uh, so what we ac- the process is actually that we bring a CNC controlled machine uptower, mount it on the yaw ring, and then we mill away that worn area, uh, creating a small pocket. And then those, uh, segments that we have designed, they are prefabricated. We bring them up and mount them in, in that, uh, pocket and bring the- The yaw ring back to where it’s, you can say, original design, uh, [00:03:00] that way.

Yeah

Allen Hall 2025: It’s better than the original design, ’cause you’re actually putting in better teeth than the, the manufacturer did originally.

Søren Kellenberger: True. Yeah, yeah.

Allen Hall 2025: So that happens, so you’re, you’re machining out those old teeth, broken teeth, putting the new set of teeth in th- and that all bolts in, and that’s it. That’s it.

But the, the difficulty is getting the machinery uptower to do that. That’s where a lot of your, your technology comes from, is getting this very accurate, uh, well-defined machine uptower and doing very controlled grinding and milling. Yes. So can you explain what that system looks like? If I’m gonna grind off those yaw, broken yaw teeth, how big is that kit?

Søren Kellenberger: It… Obviously, it depends a little bit on the turbine size. Sure, okay. Yeah. So, uh, it, so the, the newer five, six, uh, 10 megawatt turbines have larger teeth, so yeah, there you need a, a larger machine.

Allen Hall 2025: Okay.

Søren Kellenberger: But let’s say for, uh, Vestas three megawatt, the, the [00:04:00] complete machine weighs about 250 kilos. That’s it? So yeah.

So it, it comes up in smaller components. We just use, uh, the, the internal crane in, in the nacelle, and, uh, then we can lift the components to the yaw ring, assemble the machine, and then we are basically good to go. So it take, takes less than a day to get everything up and, uh, get set and be ready to, to machine.

Allen Hall 2025: So if you wanna fix a yaw gear problem, how long does it take from start to finish to get that done?

Søren Kellenberger: It typically, it takes one day to get everything up and get ready, and then per six teeth, which is a typical segment, it takes about a day to machine that. Okay. So, uh, let’s say you have, uh, somewhere between 10 and 15 teeth, it’s, uh, two to three segments.

So we do that in a week. Um-

Allen Hall 2025: Wow … and- ‘Cause the alternative is call a crane, have them lifting the cell off.

Søren Kellenberger: Yeah.

Allen Hall 2025: Take the yaw gear off, put a yaw gear on, if you can find a yaw gear. Yes. Put the nacelle back on. [00:05:00] Well, and I guess obviously the rotors are coming down too, so- Yeah. You’re talking about- Yes

hundreds of thousands of dollars in downtime. Yeah. It’s a big ordeal. The CNC Onsite method is so much easier.

Søren Kellenberger: We will just put our equipment in the back of our truck- … and then, uh, we’ll, we are ready to mobilize in a few days. So yeah, we can significantly, uh, bring down the downtime and, and as you said, the crane cost is of course extremely high.

And then you can add all the project management. You know, con- do I actually have my access roads, uh, still available? Right. Is the crane pad intact? And all of that stuff you need to organize. You can just forget about that and, uh- And

Allen Hall 2025: get it done …

Søren Kellenberger: get it done. Yeah.

Allen Hall 2025: Yeah. There’s, there’s a lot of owners, we, everybody knows who the machines are that have the, the, the yaw tooth problem.

Søren Kellenberger: Yeah.

Allen Hall 2025: So if you’re one of those owner operators, you better get ahold of CNC Onsite. Now, flanges on tower sections. It’s become a, a really critical issue. You hear a lot of, of [00:06:00] operators, OEMs talking about, “I’m putting together these tower sections and those flanges don’t really meet up quite right.”

Søren Kellenberger: Yep.

Allen Hall 2025: “I’m creating uneven torque patterns, bolt pat- my bolt tightening is not quite right.”

Søren Kellenberger: Yeah.

Allen Hall 2025: And it never really seats right, so you have this mechanical, built-in mechanical problem. CNC Onsite is now fixing that so those flanges are actually really flat. Really flat, yes. ‘Cause that’s what you need.

Søren Kellenberger: Yeah.

Allen Hall 2025: Yeah. They’re highly loaded.

Søren Kellenberger: If, if you want, uh… If you want your joints to be, uh, basically maintenance free, uh, we can, uh, achieve that with machining the flanges. And then, of course, you need to be in control with your bolt tightening process. Sure. But if you do those two things, you can have maintenance free bolted connections, and there’s so much money to be saved in the operations.

Um, and of course, when you have these bolts that end up fatiguing, some of them don’t get caught in time and you end up ha- having a catastrophic failure on the turbine. Uh- We’ve [00:07:00] seen that … because you have that zipper effect. Once a bolt starts breaking, the neighboring ones take that extra load and it accelerates really quickly.

Uh, yeah. Sure does.

Allen Hall 2025: Yeah. It’s a very serious situation, but it starts with this very simple solution which is just make the flange flat.

Søren Kellenberger: Yeah. But I think it’s some… a part of the issue is that those buying the towers aren’t necessarily responsible for the operational cost of maintaining that bolted connection.

So they might save a little bit of money when they buy the tower sections with rougher tolerances, but you will spend the money 10 times in the operations. Uh, and, and that’s, I think that’s where some of the operations, uh, re- the, the, those responsible for operational costs should, uh, get a little bit more CapEx spend, uh- Oh, sure.

Yeah. And, and then, uh, actually save a lot of money and, and reduce risk. Uh, it’s a huge, huge risk

Allen Hall 2025: It’s, it’s one of those lessons learned. You [00:08:00] don’t know that they should be flat. You shouldn’t know… You don’t know your flanges should be flat until you experience the problems, and then you want all your flanges flat from here on out.

Søren Kellenberger: Yeah.

Allen Hall 2025: But there’s only one way to do that really, and that’s to call CNC Onsite to come in and to make them flat.

Søren Kellenberger: Yeah.

Allen Hall 2025: Because it’s a difficult thing to do. You really need to have the machining prowess and the tight tolerances that CNC Onsite’s gonna deliver in a tool that can actually be adapted to that tower ring and make those surfaces flat.

It’s complicated. Exactly.

Søren Kellenberger: It is. Uh, but that is what we do every day, so, uh- Yes, I’ve noticed … yeah, so

Allen Hall 2025: so- You take on those challenges

Søren Kellenberger: So we are optimizing our machines to be not only fit for one-offs, but actually to go into a manufacturing, uh, process. So we have op- optimized our machines a lot with, uh, automatic alignment and, uh, stuff like that to, to really make that process, uh, easier.

Because it has been considered that when you had to machine a flange, you weren’t in [00:09:00] control with your production, uh, processes. But I think that is, um, a bit of a misinterpretation. It’s, it’s a little bit like saying when I have a casted component, I cannot get a bearing fit, uh, in my cast process. That’s not because your cast process is wrong, there’s just some limitations to what you can do.

Sure. And it’s basically the same here. Yes. And, and if you apply that con- uh, planned machining, you can gain some real benefits, uh, later on and the cost will, of course, drop dra- dramatically if you plan it, rather than call for one, uh, every time you have one that is out of tolerances and, and you can even narrow those tolerances down and get the benefits from maintenance-free bowler connections.

Allen Hall 2025: Right.

Søren Kellenberger: Uh-

Allen Hall 2025: Right, ’cause you’re gonna pay for it for the next 20, 30 years. Yeah. Yeah. That’s absolutely right. Now, you’re getting involved in some of the safety aspects of operating a turbine. Uh, some of the pins and the lockouts on the low-speed gearboxes get a little worn over time, so the hole [00:10:00] you put the pin in gets worn.

There’s a lot of loads on that and- Yeah … it starts to oblong out and eventually, if you’re trying to work on that gearbox, you’re trying to keep that and your technicians safe, which is what you’re doing- Yeah … that lockout pin doesn’t quite fit in the hole and it creates a little bit of a safety risk.

Yeah. So now CNC on-site’s coming in and saying, “Hey, wait a minute. We can realign that, clean that hole up, make that safe again.”

Søren Kellenberger: Yes.

Allen Hall 2025: Explain what that looks like and what that process is to do that.

Søren Kellenberger: Yeah. So again, it’s the same thought like with the, with the O-ring, uh, that instead of bringing a component down and trying to fix it, we have designed some machinery we can bring uptower and then make that repair.

So basically what we do is that, that we mill that hole a little bit larger and then we bring a bushing, uh, that we, uh, freeze into that hole- Okay … and to recreate that tight fit again with a, with a locking pin. Uh, so it’s, it’s not that [00:11:00] complicated, but you still need to know, of course, what you are doing.

So finding the center of the original hole is one of the critical things because you want the center of the new ring to be in that same position- Sure … to make sure it fits with the pin

Allen Hall 2025: right. So- Right. You can’t just take a drill up there and try to clean out that hole. No, no. That is not the way to do that

That,

Søren Kellenberger: that

Allen Hall 2025: won’t work. No, no . I’m sure it’s been tried, but- Yeah … no, you wanna have accurate mach- actual, uh, tight tolerance machinery up there to, to align that hole, drill it properly, put that insert back into that spot- Yeah … which is gonna be a hardened insert so it’ll last longer, right?

Søren Kellenberger: Yeah, yeah.

Allen Hall 2025: So once you do that, y- it’s a permanent fix to a otherwise nagging problem.

That’s wonderful.

Søren Kellenberger: Yeah.

Allen Hall 2025: So, th- again, that kit just goes right uptower, right up the, the lift, right up the cl- crane- Exactly … and bang, you’re done. Yeah. Okay.

Søren Kellenberger: So all our machines are designed to be able to be lifted with the internal crane-

Allen Hall 2025: Yeah …

Søren Kellenberger: of that specific nacelle.

Allen Hall 2025: Okay.

Søren Kellenberger: So obviously as the cells go bigger, they have more load cap- uh- Me too

load capacity. Yeah. So for the smaller [00:12:00] turbines, the machines come in, in a bit smaller parts- Okay … so that we are sure we stay within that 250 or 500 kilogram or even whatever the limit is of, of that- Yeah, yeah, yeah … crane. And then we can, uh, reassemble everything uptower and still do tolerances within a few hundredths of a millimeter.

And, and I think that is, that is really the core of, of what we do that, that we can achieve those workshop tolerances on site, um-

Allen Hall 2025: It’s crazy when I tell people that. I say, “Well, you know, CNC on-site, they can’t… I mean, those, those tolerances can’t be that tight.” And I say, “No, no, no, no. They’re talking about, you know, fractions of a millimeter,” which in, in American terms means fractions of a mil.

Yeah. That’s 1/1000th of an inch. That’s the tolerance you’re doing.

Søren Kellenberger: Yeah.

Allen Hall 2025: Uh, and that means quality at the end of the day. If you can machine things that tight, that means what you’re getting is gonna be right for that job. Yeah. It’s gonna fix that, fix that problem permanently, which is the goal. Yes. Don’t recreate the problem.

Just fix it once and be done. Now, blade root [00:13:00] inserts, huge issue. CNC on-site has been developing tooling to drill out those existing inserts and, and put in new inserts, and you’re having success with that.

Søren Kellenberger: Yeah.

Allen Hall 2025: That’s a… it seems like a complicated process, but you have owned that quite well. Talk about what that machinery looks like today, how you’re doing that process, and what have you learned from doing some, uh, field work.

Søren Kellenberger: It’s, uh… we actually, we’ve, we’ve developed two different machines now. Okay. So we, we have, we have one that is, uh, fully CNC controlled, uh, when you need to do a lot of bushings. Yeah. Um, that one takes a bit more, uh, time to set up, but, but, uh, each drilling process is, is really fast. Uh, and then we have developed a semi-automatic machine as well, uh, which is a little bit easier to mount, mounts directly on the blade.

And it’s, uh, really perfect when you only have smaller areas of the, the blade root where you don’t need to replace all bushings- But maybe typically it’s, it’s in the high load [00:14:00] area, which is 15 to 20 bushings maybe. Right. Something like that, right? Yes.

Allen Hall 2025: Yeah.

Søren Kellenberger: So, so there we can just mount it directly on the blade and, and then drill from, uh, from there.

Um, and it works really well. We completed, uh, the first large scale, uh, commercial, uh, project, uh, together with our good friends from, uh, We4C. Uh- Right.

Allen Hall 2025: Yes.

Søren Kellenberger: And, uh, and now we are producing, uh, two more drilling machines- Oh … uh, for, for new upcoming, uh, projects also together with, uh, the guys from, from We4C.

Allen Hall 2025: Wow.

Søren Kellenberger: So now it’s, it’s starting to, uh, to pick up. Um, it’s been a relatively long process, and I guess no one really wants to be the first mover on, uh, on new technology, right? Right. So we’ve had a lot of questions. Oh, that… And that looks interesting, but how many, uh, turbines, uh, or how many blades have you repaired?

And it’s been up until now, well, it’s only tested in the lab. Uh, but now we have the first, uh, large scale commercial, uh, project with, uh, 26, uh, turbines, [00:15:00] uh, repaired and, uh, and 1,000 bushings, uh, that were replaced, uh, across those, uh, 26 turbines. So-

Allen Hall 2025: Wow …

Søren Kellenberger: so I guess that is now large scale. Uh-

Allen Hall 2025: That’s large scale.

Yeah. Yeah. I would consider 1,000 a large scale test. Yeah. Yeah. Yes. And that brings all those turbines back to life.

Søren Kellenberger: Absolutely. They are up running, uh, full power again, so, uh, that is, uh-

Allen Hall 2025: That’s huge …

Søren Kellenberger: really nice.

Allen Hall 2025: For the operator, I’m sure they love that.

Søren Kellenberger: Yeah. And, and of course, uh, there’s, there’s been a lot of discussions about blades and, uh, bla- the, the waste, uh, issue you have on, on worn- Oh

out blades. Sure. So by being able to fix them instead of replacing them, not only is the, the cost for fixing a blade a lot lower than buying new ones, uh, but, but also from a, an environmental perspective. The not having to scrap them and create that waste is, uh, is also a nice, uh,

Allen Hall 2025: thing. Yeah, it’s one of the things that pops up more recently about replacing blades, and I think the [00:16:00] industry and the operators are pushing back on that.

Uh, because a lot of times the OEM wants to replace a blade, it’s just easier for them to do.

Søren Kellenberger: Yeah.

Allen Hall 2025: But the reality is, is that yeah, you’re creating this additional problem. What are you gonna do with the disposal of this blade? Do we really need to do that? Is it so far gone that I can’t recover it? I think a lot of times, especially with fiberglass blades- Yeah

you can bring them back to life.

Søren Kellenberger: Yeah.

Allen Hall 2025: Just with a little bit of engineering, uh, prowess and some good machinery- Yeah. You can, you can make magic happen, and that’s what CNC OnSite is doing. So that, that’s really amazing that, uh, you’re starting to get more adoption of that on, on the blade root inserts. I know across the United States there’s all kinds of issues, and you’re proving it out.

I think the adoption rate in America and all over is gonna really step up. Now, uh, you always have some cool new project, sort of top secret. What are you working on that the world needs to know about?

Søren Kellenberger: Yeah. W- I mean, we are constantly, uh, [00:17:00]expanding our, our line of services. Uh, so- Sure … so we are just out there trying to listen to what kind of issues do we see in, in the industry-

Allen Hall 2025: Yeah

Søren Kellenberger: and how can that be fixed, uh, uptower. So, so some of the, the latest, uh, innovations we’ve been doing is a, a new machine on, um… to, to do shaft milling. Uh, so that c- that can be on generator shafts, uh, for instance. There are some machines out there, but we’ve decided to go, uh, against CNC control- Okay

because it gives us a lot of, uh, opportunities both on, on speed, uh, of the process. It’s a more safe, uh, way to, uh, to do it.

Allen Hall 2025: Sure.

Søren Kellenberger: And we can actually also do different, uh, shapes on the shaft, so, so we can do more advanced, uh, repairs. Okay. We, we don’t need to stick to a certain diameter all the way. Now we can, we can mo- make grooves, and we can do, uh- Really?

all sort of sorts of stuff, uh- Oh … along that process because it’s CNC controlled.

Allen Hall 2025: Oh, sure. Okay. Um, and- Boy, okay. That makes a lot of sense. So you can actually take a, a, a basic, [00:18:00] basic, basic design of a shaft and make modifications to it- Yeah … to extend the lifetime and make it work better.

Søren Kellenberger: Yes. So typically we would mill down, uh, the shaft and- Sure

install a sleeve- Sure … to recreate a, a bearing fit, for instance.

Allen Hall 2025: Right. Yeah.

Søren Kellenberger: But we have possibilities to, uh, to create, um, grooves or anything that would do a stress relief or whatever you need, lubrication, or if you, if you want to do something, uh, afterwards, we, we can do that with, uh, with our machines.

Uh- Yeah. So yeah, we, we have some new machines for, for hollow shaft, uh, machining, so we can do stuff, uh, inside the main shaft, for instance. We can do stuff on the, the outside, as I mentioned on, on the generator shaft, but that could be on the gearbox as well. So- Sure … sometimes we see issues on the main shaft to, to gearbox, uh, connection.

Allen Hall 2025: Yeah.

Søren Kellenberger: We are able to, to fix, uh, those, uh, things uptower. Wow. And, uh, so yeah, lot of new, uh, stuff being, uh, developed.

Allen Hall 2025: That’s, that’s awesome.

Søren Kellenberger: [00:19:00] Yeah.

Allen Hall 2025: And I, I know you guys are busy, but- If somebody wants to get ahold of CNC Onsite and get work done this year, they better be making phone calls to you- … quickly. So I, I know your order book is filling up and you’re, you’re having to devote crews and machinery and time.

Yeah. How do people get ahold of you and get on that contact list and can start working the process?

Søren Kellenberger: I would say go into, uh, cnconsite.dk and, uh, there we have all our, our contacts. Uh, so just reach out. There’s a, yeah, formula you can, uh, fill in, uh, or you can find our direct contacts in our webpage, and, uh, then we can start looking at it.

So we are quite busy, but we are always- Yeah … open for, uh, discussions and, uh, yeah. That,

Allen Hall 2025: that’s a problem with being successful, is you’re just always busy running around trying to take care of problems, and that’s the thing, is that everybody I talk to that’s used CNC Onsite loves it-

Søren Kellenberger: Yeah …

Allen Hall 2025: and loves the process and loves the work you do.

So there’s gonna be a lot more phone calls and a lot more orders coming your way, and that’s- Yeah … that’s awesome. [00:20:00] Soren- Yeah … it’s so good to see you again and it’s so good to see you in person. Yeah. And congratulations on the promotion and everything that’s happening at CNC Onsite.

Søren Kellenberger: Thank you, Allen. It’s a pleasure.

CNC Onsite Cuts Repair Costs With Uptower Machining

Renewable Energy

Is the Damage Permanent?

Published

14 hours ago

May 6, 2026

Alice Rush

Nobody knows.

Without doubt, the damage is profound. The world has recognized that the United States is being commanded by a madman and has abandoned its place as the leader of the world.

As we look back across history, we see a certain shelf-life to democracies. It’s easy to believe that we’re in the final days of what became of ancient Greece. It’s also possible, as numerous scholars have asserted, that we’re on the precipice of the sixth extinction.

But it’s entirely possible that the pendulum may start to rebound toward the days of America’s greatness, the time of truth and fairness.

We’ll see.

Is the Damage Permanent?

Renewable Energy

Are You with President Trump?

Published

15 hours ago

May 6, 2026

Alice Rush

A dwindling number of hateful idiots still cling to the ideas at left.

But what was once 77 million is now approximately 45 million, and that number is falling every day, as Trump leads us deeper into corruption, economic ruin, and the revulsion of our former international allies.

Maybe we’ll see a meme like this in a month or so, when the president’s approval rating has declined into the teens, but I doubt it.