Connect with us

Published

on

Søren Kellenberger, sales director at CNC Onsite, joins the Uptime Spotlight to discuss their uptower yaw ring repair method. He describes the root causes of yaw ring failure, makes projections for the future, and introduces CNC Onsite’s patented yaw ring repair solution. Their portable precision machine can be lifted uptower to replace a damaged yaw ring, potentially saving operators significant downtime and repair costs.

Fill out our Uptime listener survey and enter to win an Uptime mug! Register for Wind Energy O&M Australia! https://www.windaustralia.com

Sign up now for Uptime Tech News, our weekly email update 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 Facebook, YouTube, Twitter, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary Barnes’ YouTube channel here. Have a question we can answer on the show? Email us!

Pardalote Consulting – https://www.pardaloteconsulting.com
Weather Guard Lightning Tech – www.weatherguardwind.com
Intelstor – https://www.intelstor.com

Allen Hall: When wind turbine yaw gears fail, operators face a costly choice. Hire a crane for a complete replacement or attempt a risky repair. This week we speak with Søren Kellenberger, sales director and partner at CNC Onsite. CNC Onsite brings precision machining up tower. Making yaw gear repairs faster and more reliable without using an expensive frame.

Welcome to Uptime Spotlight. Shining light on wind energy’s brightest innovators. This is the Progress Powering Tomorrow.

Allen Hall: Søren, welcome to the show. Thank you very much, Allen. And thank you for inviting me. Well, we want to understand first, what is causing yaw gear to break? teeth to be damaged in some of these turbines, because the photos I have seen are remarkable. The teeth are just gone. How does that happen?

Søren Kellenberger: I think there can be a number or there can be a number of reasons.

And it, it depends a little bit, I think, on the turbine, how the yaw ring was designed and stuff like that. But if you look at some of the older turbines the yaw ring. Wasn’t hardened. So there, in many cases, you’ll just see wear and tear from years of of use, operation. And typically in a, in a wind farm, you have a dominating wind direction, right?

So, Especially in Denmark, it’s mainly blowing from the west. So all our wind turbines are pointing that direction most of the time, which means that they are yawing within a limited area of of the yaw ring. So a limited area is taking the majority of, of the wear cycles. So, so therefore they, you, you see some, some local wear and tear and, and finally they will be worn down razor sharp basically and, and break off eventually.

So, so that can be, be just one cause of, of the, of the failure. We also see sometimes that even though they are hardened, they, of course, they don’t wear that much, but they will more break off and probably. Due to some extreme loading and I guess that can be caused by either some, some misaligned yaw gear it can be extreme loads.

You have some sites where you have Really wind directions changing very fast that is causing unforeseen loads on the turbine. So you have actual extreme loads that are, that are higher than the design loads. You could probably also sometimes see foreign objects that are, are falling into the, to the ying and being squeezed between the ying and your gear, causing some, some damages.

So. There are a number of, of different reasons for, for these damages, I guess.

Joel Saxum: Do you see anything environmental? Like in my mind, I think of these Arctic turbines, right? The ones that are operating in this, in the extreme cold. When, when metal gets cold, it gets brittle. Do you see more, more yaw teeth get damaged in those territories as others, or is it just kind of across the board the same?

Søren Kellenberger: No. We haven’t seen that, that these cold condition turbines are affected more than than others, but we do see that the weather conditions play a significant role. And. If you have maybe your ring damages on two to 5 percent of, of, of your turbine fleet, then they will not be evenly distributed across your different parks.

It tend to be that if you have an effective park due to some special weather conditions in that area, you seem to have a lot of problems in that one park, and you can have other parks that will run perfectly fine for, for your the entire lifetime without any issues on, on the yaw ring. Well, at least these inspections aren’t super difficult.

Yeah, it’s pretty obvious when they are missing.

Allen Hall: What’s the effect when they’re missing teeth like that? Is it, is, is the turbine just not able to yaw anymore or is it, it really, it risks some structural overloading when that happens?

Søren Kellenberger: Yeah. I mean, in in the beginning, I guess you, you won’t be able to, to yaw.

So at least you, you, it would be less accurate if you have. where it will start being less accurate. And that will of course cause some loss production. Potentially if, if you are misaligned on your, your system, you’re also introducing unwanted loads to your, to your turbine. So I guess it could have also other consequences when you are other than.

Just lost production when, when you have a yaw misalignment. But yeah, in, in the end you won’t be able to to yaw the turbine if you have too many damaged teeth.

Allen Hall: So is the turbine sent out an alarm when that happens? Is it just a, a complete shutdown? The turbine just says no more. I can’t move and I’m stopped or it doesn’t recognize that this is even a failure.

To be

Søren Kellenberger: honest, Alan, I’m not 100 percent sure. And I think it depends also on, on on the turbine how, how, how new or old they are and how advanced their control systems and condition monitoring systems are. Some of them, they just have on off on the, on the yaw gears. And, and they won’t recognize that, that one yaw gear is just spinning in free air but you can have others that have more advanced control systems where, where you can see that some of the yaw gears are suddenly using a lot more power to to yaw the turbine, which will indicate you have some kind of yaw issue.

If it’s a bad yaw. A broken yaw gear or if it’s some teeth missing in that area where that yaw gear is placed you, you can’t probably tell, but, but there are different warning systems possibilities, but again, depending on how old or how advanced your, your turbine is.

Allen Hall: Wow. So this is really serious.

It’s just beyond just the tooth missing. The consequences for the chairman can be quite dramatic. Now, CNC on site, obviously, is all about doing machining. How do you go about fixing this problem?

Søren Kellenberger: Basically, we have a a smaller CNC controlled, three axis CNC controlled machine that we bring up tower and these machines are adapted to the different different requirements.

Turbine types. As you can imagine, the turbines were not designed for these kinds of repairs. So the design engineers originally didn’t leave much space for for a machine in those areas. But so, so we, we customize the machines to fit the different turbine platforms and, and. Basically we use the internal crane of of the turbine to hoist the, the machine components to, to the turbine.

Use the internal crane to, to position it at the yar ring. And then we mount the machine on, on the Yar ring itself. Which also gives us the advantage that even if the turbine is moving a little bit due to, to wind we are moving along with it. So it doesn’t influence our our accuracy when, when machining.

Allen Hall: That’s quite impressive. Cause the alternative is, and what I’ve seen is you lift the whole, you take the blade set off and then you lift the whole in the cell off and then you go in, you try to replace the yaw gear, which is super expensive.

Søren Kellenberger: That is, that is very, very expensive.

Allen Hall: Yeah. So you’re really talking about taking up some precise machining equipment up tower.

Doesn’t really matter if the wind’s blowing or not. You’re, you’re fine. You’re all inside. And you’re going in and machining what remains of those teeth. I mean, I, I want to have a sort of a dentist equivalent of this. So it’s like you have a broken tooth and, and the dentist comes in and goes, okay, we’re going to grind that tooth off and we’re going to smooth out.

And we’re going to put a replacement. On top of it, like a crown, right? It’s basically a crown. So that process takes how long to do once you kind of uptower in your starting the machining process.

Søren Kellenberger: If we if we use like the, the Vestas V90, three megawatt platform as a sort of baseline then it takes we have, we have our, our teeth segments, our crowns.

If you, if you want in in segments of of six teeth and it takes roughly one day to once we are open and ready to, to replace six teeth. So for a replacement, you need to consider one day of hoisting and getting in place and then. One day for, for each segment you need to, to install and then one day to, to pack up and clean and get back down.

So so we, we get quite a fair bit done in a week.

Joel Saxum: Yeah, that’s, that’s impressive. So, so there’s a couple of activities here that have to be done, right? Of course, you’re getting up there, you mount the CNC equipment. That’s one big part of it. But then you’re, you’re, you’re milling up tower. So you have to deal with, you guys have a, you have a system to deal with all the filings and tailings and catching all that stuff.

And then, and then once you put the new teeth or the new teeth get in place, is, are they welded in place or how are you, how are you attaching that?

Søren Kellenberger: No we bolt them in place. So that because we have a CNC machine, we, we, we can do a very accurate milling process up there. So, so. So basically we, we, as you say, we, we remove the, the remains of, of the old teeth and, and we machine like a pocket in, in the yaw ring.

And that one is milled within a couple of hundreds of millimeters in tolerance. And then we have the benefit because we know the design of the yaw ring. So we. We bring prefabricated segments that have the exact same shape as, as the original yaw ring. And, and they are of course manufactured in a, in a machine workshop.

So, so they have very good tolerances as well. And then we basically create a press fit. So we either slightly pre bent the segment to, to install it or we, we freeze it. We have some small freezers we can bring up tower as well and cool the segment down to minus 80 degrees, which gives us just enough space to, to easily fit it.

And then as it heats up, it’s a, it’s a press fit. And then we keep it in place with bolts as well.

Allen Hall: Wow. I didn’t realize it was a press fit. That’s insane. That’s better than the manufacturer delivered on site when the turbine was new. Yeah, it could be. The other way I’ve seen this repaired, if you watch LinkedIn enough and Joel and I are constant viewers of crazy LinkedIn wind turbine repair videos and Instagram, there’s a lot of this in Facebook too, when they have broken teeth, you see guys up there with welders and they’re up in there and they’re adding filler, trying to rebuild it, trying to reshape it.

Then you see them grinding on this gear. What are the problems with doing that approach?

Søren Kellenberger: We do actually also work with some welding companies, but because you can have some situation where welding is your only opportunity, but, but we can, we can get back to that. But, but the, the challenges with welding is of course you have a big, massive, steel ring so it absorbs the heat quite fast.

So controlling the the heat and the temperature in, in your welding process is is difficult. The space is just as limited for, for welding and they need to fit a person in there. So so you also have the disadvantage of, of having like hot works and confined space, which is, is not so nice.

And then finally being able to grind those Teeth into the original shape is also relatively challenging. You don’t have much space when you are in there and you would want to try and get that contact surface quite straight to distribute your, the load from, from your York year when you start operating again, and, and I think that probably the most challenging part where we have the benefit of, of machining, bringing a pre machined segment that has that exact shape.

I think that is probably one of the, the biggest benefits to, to, to our process. And, and because it’s such a manual process of, of grinding, it can be difficult to get that shape. And, and that can be, Can give you some extra loads on a, on a welded tooth which can lead to damages again faster than, than what we see on,

Joel Saxum: on segments.

There’s, I mean, there’s one thing for rebuilding teeth on like an excavator by welding, welding up a bunch of metal and, but, but, but teeth that need to be used in a, you know, basically a ring and pinion set or a ge you know, a a tooth gear thing. It’s gotta be exact. It has to be, because if not, you’re just gonna be back up there in a year or two.

Doing the same process because it’s just not going to last. It’s temporary. Does the, there’s

Allen Hall: a yaw motor gear and all the machinery that’s there and the mechanism there, does that need to be updated too? Because it’s been working against these, these gears that have been not the right shape for a long time, that in order to get this really fixed, you need to put the proper.

teeth in the R gear, but also on the motor, you need to take a look at it and make sure it’s up to snuff. Yeah,

Søren Kellenberger: I think that is a typically also a part of the inspection. They, they do that. They, they check that all the motors and, and gear wheels there are okay. It’s normally not a part of, of our process to do that, that, that would be the turbine owners or the, their own technicians who would check that.

Up front or, or right after we, we complete our work. So, but yes I mean, when you are up there fixing it, I, I, I would definitely recommend that you check the remaining system and potentially also try to look for the, for the root cause if you do have. Misaligned your gears or something like that.

It could for sure be an advantage to to get them aligned to avoid having the same damage again soon after the repair. So how many of

Allen Hall: these teeth replacement are you doing in a year? Because my guess is it’s a good Quite a number from what I’ve seen out in the field,

Søren Kellenberger: you can say it’s still a relatively new technology, even though we’ve been doing it for five years.

It’s still a conservative industry. You know, they, they want to see new technology introduced and, and see how it operates and works. So it’s not that we do a oaring every. But we we have installed more than a hundred segments since we started and, and we see that it is taking off now the first segments have now been running for more than five years and, and proven them themselves very well.

So, so we, we certainly do and also you see that. The turbines, the number of turbines that are reaching that age where you can could expect some, some wear or damages to your, your ring is also increasing significant significantly. So we, we will be seeing more repairs over the coming years for, for sure.

Joel Saxum: I think that’s a big part of the conversation here is you know, looking, looking in the European market, like if you look at Spain right now, their fleet is starting to get to that Close to end of life or life extension. What does it look like? Is it repower? Is it refurbished? How do we keep these things running?

And Alan and I just had a conversation with a company here in the States that’s doing a lot of repowers just the other day. And I was thinking about that there too, because in the States we have this, you know, PTC driven repower thing where you could put certain amount of value back into the turbine, still qualify for some subsidies.

And I was thinking, man, with all these older turbines. What else can be done here? And some of that would be refurbish, refuel, fix these raw yaw gears, fix these kinds of things to make sure that you’re, you’re maintaining that level of performance that you want. Or, I mean, if you’ve been operating like this for a long time, you may be getting back to back to baseline as well.

I mean, at a minimum would be nice to get that out of it. So I think that the market for what you guys are doing is going to grow massively. Globally right now, right? We’re seeing, we could see a lot of applications from here for it in the States with our 75, 000 and change turbines we have plus that European market that’s changing.

So are you guys starting to get some calls from, you know, how, is it, is it more like damage during regular operation and this is what’s happening or, Hey, we’re at getting close to end of life. Can you help us do an assessment on what this looks like? Are you getting those calls? Both. Yes.

Søren Kellenberger: So, so. Most most operators I guess they, they start really looking for this when they see an issue but if they have had turbines or in other wind farms, for instance, or, or even some of them that, that have been damaged earlier in the lifetime, they are more aware of these issues and, and they would also contact us for, for inspections and, and evaluations if, if what can be done and, and to get some, some budgetary quotes and, and stuff like that to see if there’s a return on, on investment within their potential lifetime extension.

So, so yes, we, we do get both And, and I mean, we’ve been in, in Japan to, to fix teeth on a, on a turbine. We’ve, we’ve been across multiple countries and in Europe we’ve just sold a machine to New Zealand together with the first 25 segments. They will, they will get together with this machine.

So it is picking up around the world. And, and we also have several inquiries from from the U S so, so I would be very surprised if we weren’t doing some turbines in, in the U S next year also on, on the Jolring site.

Allen Hall: So can an operator buy the machinery and do this process themselves with your direction, of course?

Or is it always required that CMC on site people be there to do the process?

Søren Kellenberger: No, it’s a, it’s not a requirement that, that we operate a machine. It, it is a very much a case by case discussion with with our customers, if, if they have The technicians with the right skills and, and they have the volume of turbines to keep them up to, up to speed on, on using these machines.

It can make sense that they buy a machine and we train them. Others prefer that, that we come and do an all inclusive service. So it is, it is basically up to, to the customer. And, and we discussed that case by case how, how we make the best project.

Allen Hall: What process is used if you’re offshore on these massive 8, 10, 12, now 15 megawatt turbines?

Is the process basically the same on those turbines?

Søren Kellenberger: It is. Completely the same process only, only difference is is, is the transport there that we have to go by CTV and not not a, not by car. So that, that is basically the only difference if the turbine is onshore, offshore, doesn’t make any difference for, for us.

It is still the, the exact same milling process and yeah. installation process. We don’t need any other external equipment.

Joel Saxum: How big is one of these kits? Like, if you’re going offshore, if you’re transferring, I know like, on offshore, on the transition piece, there’ll be a little crane sometimes and stuff, but like, how, like, weight and dimensions, what, what does it look like?

Søren Kellenberger: That depends on on the turbine. As I mentioned before, though, most of these turbines weren’t designed for this kind of, of repair. So, so we don’t have a one fit fits all machine. And, and the segments are also different because the yaw ring in a 8, 10, 15 megawatt turbine is, is way bigger.

Bigger than in a two or three megawatt, of course. But if we take the, the two, three megawatt size turbines, our machine is around 80 kilos. And the segment is weighing eight to 10 kilos. So it’s, it’s, it’s easily transferable. And we always make sure that we can, if the machine is too big or heavy when it’s assembled, we always make sure that each component can be handled by the internal crane and go through the hatch in, in in the nacelle.

Because that is very important also. And, and in terms of keeping the cost down that you don’t need any external cranes for, for this operation. But I think our, our heaviest machines for these large offshore turbines is around two, 300 kilograms. So when they are fully assembled.

Joel Saxum: So for me, if I’m, if I’m, if I’m an ISP in the States and I’m listening to this podcast, I’m thinking, Ooh, new service line.

I need to get ahold of Søren. And so I can, so I can be the, I can be the person that gets called in the States to do this. And

Allen Hall: Søren, how do people get ahold of you? How do they reach out to CNC onsite?

Søren Kellenberger: Either through our, our website cnconsite.dk where we have all our, our contact details listed or directly to me at my email ssk@cnconsite.dk or call me.

Yeah, the, my phone number is also also on, on the website. So, there they are most welcome to to reach out to us.

Allen Hall: It’s amazing technology and it needs to be utilized across the world because I’ve run into a number of operators with yaw gear problems and they’re stuck and they didn’t realize you existed.

So hopefully this podcast gets to them and we can connect you up and get you busy because there’s a lot of yaw gear repairs that need to happen over the coming repair seasons. So. Søren, thank you so much for being on the program. Joel and I have learned a ton. Thank you very much for having me.

https://weatherguardwind.com/cnc-onsite-yaw-ring-repair/

Continue Reading

Renewable Energy

NOAA Set Up Website — for You

Published

on

Trump is working hard to dismantling NOAA, the National Oceanic and Atmospheric Administration, the largest collection of American scientists focusing on climate change.  He proposed a budget cut of $1.7 billion, or about 27% for 2026. More to the point, he shut down NOAA’s website, that, formerly, gave everyone on Earth the ability to look at key climate-related data.

In response, those scientists, knowing that we can no longer trust the U.S. government for real climate science, have set up Climate.us

More here, from NPR.

Looks great to me!

NOAA Set Up Website — for You

Continue Reading

Renewable Energy

Why Write?

Published

on

Here’s a short video that explains why we write.

Like the farmer planting to the seed, we do not know if it will grow into a life-giving plant, but we believe that it’s possible.

Why Write?

Continue Reading

Renewable Energy

Japan Backs Floating Wind, US Grid Sidelines Clean Energy

Published

on

Weather Guard Lightning Tech

Japan Backs Floating Wind, US Grid Sidelines Clean Energy

Japan and the UK sign a $12 billion floating wind deal for 5.9 GW, Muehlhan buys Coverwind Solutions in Spain, and US grid reform stalls as MISO, PJM, and SPP fast-track fossil resources over wind.

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!

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

Allen Hall: Welcome to the Uptime Wind Energy podcast. I’m your host, Allen Hall. I’m here with Rosemary Barnes, just back from Japan, in Matthew’s stead. Yolanda Padron is on special assignment. Well, Rosemary, what happened in Japan? You, you spent a, a week touring the country and looking at, uh, some energy projects.

What did you learn?

Rosemary Barnes: I was there for just five, five nights. I went over for an, um, an, a systems engineering conference by INCOSE. I was doing a keynote presentation there, and also spoke to some of their… They’ve got this program, an international programming for, like, upcoming leaders. Um, and yeah, it was funny, the topic that I chose for [00:01:00] that was how you can combine an online presence with a serious professional career.

Uh, ’cause, you know, like, a lot of the advice that you see about building an online presence is, like, totally compat- incompatible with being taken seriously in a, uh, you know, in a, a job like engineering. So that was pretty fun. And then on the last day, I was able to arrange a tour of a community. Like, we went to this village near Fukushima, and they, a- after the Fukushima, uh, or the earthquake that led to the Fukushima, uh, shutdown, that town, some power lines came down, and that, that village was without power for three months.

So in response to that, they’re like, “Community power for the win.” At this place, like, there was literally steam coming out of the ground just, you know, randomly. It’s an onsen town, so you know, like, it’s, um, it’s built around tourism for these hot baths. And so they put in a couple of geothermal power plants, small ones, and, um, also some hydropower.

But the reason why I wanted to go there was ’cause, you know, ge- [00:02:00]geothermal is such an obvious solution for Japan, for the energy, but they only have… .3% of their electricity is generated by geothermal currently. And, um, the main reason is that the onsen community in Japan is really opposed to it. They’ve lobbied against it because they’re worried that, um, you know, the onsen community needs heat to come out, hot water to come out of the ground, and geothermal takes hot water out of the ground, so they’re just worried that they’re incompatible.

Um, now I think the science says that that’s not really true, that the, there isn’t, they’re not the same resource and that one doesn’t affect the other. The wastewater from the geothermal is not really wastewater. It’s just water that is not as hot as it was when it came up. Um, that goes down then into the onsen because it’s a good temperature.

And then some of the even cooler water, about 21, 23 degrees, they’re using that to raise shrimp.

Allen Hall: Well, just speaking of Japan, uh, the Japanese Prime Minister was just in the UK and a [00:03:00] big deal was signed between Japan and United Kingdom, £9 billion worth, which is about 12 billion US dollars, uh, to work together on 5.9 gigawatts of floating wind capacity in the UK, uh, across three different projects.

W- And the goal is to get some Japanese partners working with, uh, the UK companies involved with it to suss out how to do offshore wind. And as we all know, Japan is gonna, is headed there right now and is going to need a little bit of a primer on how to do it. And, and, well, they should because, uh, there’s been some really successful efforts in the UK and up north, Northern Europe.

Uh, so the, the goal of this is to, to get these projects underway and, and Japan’s committing all this money, which, uh, sure, it’s a nice boost to the UK at the moment. It gets a little turbulent over there if you’ve been watching the news. Rosemary [00:04:00] Tying back to your experience in Japan recently, is there a big push internally?

Do you see that internally in Japan for offshore wind and even offshore floating wind in Japan, or are they really prepping for it in country?

Rosemary Barnes: Yeah, I’d say I went over there thinking that Japan was, like, oddly not bothered about wind energy of any flavor. Um, ’cause, you know, like onshore wind, they’ve got problems because the good ri- wind resource is right on the ridges, and they’re getting just hammered by lightning, and they’ve got some, like, really interesting responses to how they think that they should manage that, that in my opinion are just gonna kill…

Like, you would never bother to have an onshore wind farm if these, um, regulations go ahead. So offshore they have got, um, a bit of a, an, a fixed bottom resource, and they’ve had several auction rounds geared towards that, but they’re, um, they haven’t gone well. I think that, like, people have promised… It, it’s a similar story to elsewhere in the world.

Uh, people have, like, bid, like, [00:05:00] bid down to quite low prices and then not been able to deliver and pulled out. Mitsubishi just recently paid some, uh, some huge penalty for not going ahead with a, a project. There isn’t actually that much fixed bottom potential, um, for Japan. So, um, if they wanna have a significant amount of wind energy in their grid, which they should, because they’re, like, honestly it is probably the best or one of the couple of best options to provide big chunks of their electricity supply, then it needs to be floating.

Um, and the government is actually pushing on that. I thought they weren’t doing too much, but I did talk to someone from this group, Flora. It is a group that is, um, that, that is trying to form partnerships with other countries, but also with manufacturers to try and set the framework up so that it can, like, l- lay the groundwork for commercialization to happen without being prescriptive.

Flora is in there [00:06:00] to try and, you know, get the pieces in place to be able to allow, um, you know, uh, innovation and competition to happen much, much faster.

Allen Hall: What’s the most complicated piece technically that needs to be solved before Japan can really move forward? Is it the money piece? I mean, um, um, I said technically, but I feel like there’s always this money aspect to it, which is important, but on the technology side, i- is it, is there any technology that remains to be solved or is it just the will to do it?

Rosemary Barnes: Basically in any engineering question, the answer is money, like, when you come down to it. So, like, it’s almost boring to say, yeah, it’s, it’s money. Floating offshore wind- Too hard, too niche for most people to consider it a mainstream thing, but it’s the legitimate, like, good contender for Japan. And you know what?

That presents opportunity. It can actually be good to have to do something hard. Um, and Japan has the opportunity to be the [00:07:00] country where, you know, it’s the country where floating wind makes the most sense, so they can be the ones, if they’re smart about it, they can be the ones where the smart technologies evolve.

There will at least be little niche things that they develop that will go on to succeed, and Japan really needs some new big manufacturing industry to… Like, their car industry is obviously, um, has been so important, the automotive manufacturing, and it’s declining now relative to China. Um, so I am also hopeful that they can, you know, build that up a bit more, but I don’t think that they’re going to, you know, topple China, so they are looking for new industries that will be the new…

Yeah, do for them what the auto industry did from, yeah, from the ’70s onwards. Actually, you know, like, you can tie it back in a nice loop back to the oil crisis in the ’70s because that’s when the world was like, “Oh, actually small, efficient cars are, are quite a smart idea.” And Japan had those because it was so [00:08:00] constrained in terms of, you know, the oil that it could bring in was expensive.

Not having their own fossil resources, they learned to conserve it, and then that turned out to be, you know, a big advantage for them.

Allen Hall: Using the 1970s gas price crisis and the movement towards Japanese cars in the United States, I mean, timing is everything. And Japan was in, uh, Honda in particular, was in the United States.

I think Toyota was too, if I remember correctly. And when gas prices went through the roof, uh, yeah, they were very efficient cars, and not the most reliable at the moment, but obviously they’ve changed quite a bit and s- they are, particularly Honda and Toyota, are probably two of the more reliable blan- brands you can buy in the States today.

So things change, right? You’re just getting your foot in the door. But that, that break point is, is coming pretty soon, I would say, in, in terms of timing. I- is it the right time for Japan to move into floating offshore? It’s gonna be within the next couple of years, don’t you think, Rosie?

Rosemary Barnes: Yeah, yeah, def- [00:09:00] definitely.

Um, and yeah, I mean, I, it, it, it does frustrate me that any money is being spent on, um, hydrogen and ammonia imports. I, I would just rather that they just, just, just do the LNG until you figure out alternatives.

Allen Hall: That makes more sense.

Rosemary Barnes: Gas is better than… You know, like ammonia, for example, they’re locking in these coal power plants for additional years, making investments, um, you know, thinking that this is gonna be part of their future.

They’re gonna end up burning coal, y- you know? At least gas is flexible enough to support renewables, and so it can, you know, like speed the rollout of, of wind. And they do have a fair bit of solar too in Japan. Floating solar, actually. They invented that there, and have actually got quite, quite a lot of it.

Allen Hall: Gas is gonna be the answer short term. I think in the relationship between the United States and Japan has always been pretty solid since after World War II, that the United States would be willing partners to help Japan stand up any [00:10:00] technology, probably except for wind, which is just bizarre.

Rosemary Barnes: One of your maybe, um, unexpected legacies in Japan was, I say you, I mean the USA, they’ve got, um, not just the, like, silly American power plug design where you’ve got, like, the parallel pins that just fall out, so they’ve got that.

But they also have 110 volts. Like, where else in the world is, is, thinks that’s a good idea? I had, um, my little travel steamer I’d taken over there, hairdryer, useless. Absolutely useless.

Allen Hall: That’s all you

Matthew Stead: need.

Rosemary Barnes: I blame you personally, Allen. I hold you personally responsible for my wrinkled clothing.

Allen Hall: Delamination and bondline failures in blades are difficult problems to detect early. These hidden issues can cost you millions in repairs and lost energy production. CIC NDT are specialists to detect these critical flaws before they become expensive burdens. Their nondestructive [00:11:00] test technology penetrates deep into blade materials to find voids and cracks traditional inspections completely miss.

CIC NDT maps every critical defect, delivers actionable reports, and provides support to get your blades back in service. So visit cicndt.com because catching blade problems early will save you millions

Well, the wind service sector is consolidating as we’ve all watched over the last year or two, and Mjolner Wind Service is one of the most aggressive buyers in the field. Uh, the Danish company has signed to acquire Cover Wind Solutions of Spain, including Cover Sun Solutions and Cover Renewable, with the deal expected to close by the end of June.

This is Mjolner’s 11th acquisition since 2023. Now, Cover Wind fills a geographic gap for Mjolner. Uh, they are [00:12:00] involved in Spain and France and, uh, already involved in covering the Nordics a little bit and Central Europe. So there’s a, a big play here, and, and decommissioning is really the, the story underneath of th- all this is on the decommissioning side.

Uh, Mjolner views turbine end-of-life services as an important future growth area, and obviously it is. Particularly in Spain, there’s been a lot of turbines that will be, uh, brought down and new turbines put up in the next 10 years, and Cover Wind gives Mjolner that ability. And as we all know, Mjolner just recently acquired our Canadian friends, AC883.

So yeah, they have been on quite the spin recently, and that’s not even Yeah, sl- a sliver of what’s happening on the consolidation effort, uh, we didn’t talk about last week, but we, we should have, which was Fairwind acquiring Rope Partner in the States. And Rope Partner is a [00:13:00] longtime blade repair company and has been seen for years, as long as I can remember honestly, as the go-to blade experts on complex repairs.

The, the, the most trained up, most, uh, technicians. On the technician side, they’re, they, they, they always had the highest trained people to what I remember, and also they would ta- tackle some of the most complex blade problems, and now they’re part of Fairwind. So there is movement, Matthew. A, a lot more than I thought there would be, because after COVID, a lot of companies just disappeared, but now it does seem like they’re being acquired, which is a, a good result, I guess.

Matthew Stead: Yeah, I think there’s a strong opportunity, and, uh, and maybe the first point is that actually doing an M&A successfully is actually really hard. Um, I, I’ve personally been through two, uh, two M&As, um, and it is, it is really hard to get an M&A right. And so I think, you know, [00:14:00] these companies are showing that, um, you learn, you can do better, and, you know, it, it, it is hard.

So congratulations for them for achieving that. Um, but the second part I think is also, you know, the industry maturing, uh, gaining scale is also, you know, necessary and, you know, driving, you know, but– and these people should be able to drive their, you know, better margins and so forth through, through scale.

So, you know, I, I think, um, I think we had a bit of quick chat about it previously, but, um, this is, you know, a really good thing.

Allen Hall: Does it change the way we think about, uh, independent service providers?

Matthew Stead: Yeah, I think it’s gonna continue. I mean, this is not the end of it. Um, you know, in– even in what we do, there’s been various, you know, mergers and acquisitions in, in our space or, and investments, you know, cross-investments.

So I, I just see this continuing. You know, like SkySpecs, um, you know, growing their, their CMS, um, business and their financial arm. Um, this is just gonna continue.

Allen Hall: [00:15:00] Is it more activity, uh, related to the availability of AI? It’s– It does seem like that’s playing into some of the decisions that are being made on the mergers and acquisition in renewables, is you start to see more discussion of, hey, we’re going to, uh, apply new techniques, machine learning.

A lot of times you’ll see that, particularly in Europe, and then here in the States it’s almost all AI, where they’re- In order to have a, a very successful AI venture, you need to bring in the brainpower to feed that AI. And it does seem like there’s a lot of, of senior companies getting grabbed that could be part of a larger artificial intelligence play.

Matthew Stead: You remind me of the, um, the dotcom boom and bust. I don’t know. I’m, I’m a little bit more skeptical, um, on the value actions on the, on the AI side of things.

Allen Hall: Really?

Matthew Stead: It certainly… It’s a massive, um, massive, um, transformation for the industry, and you know, I mean, what I, what, what we can all do is, is massive.

[00:16:00] But, um, my former employer, a consulting business, bought a AI company for a billion dollars, and I, I, I just can’t see the value. So, um, anyway, I’m, I’m a bit skeptical about valuations and AI, and, um, I’m not as bullish as many people are.

Allen Hall: Really? Uh, because it does seem like more recently, the shift has been from the number of engineers you have in your company times a million dollars a head, that’s the way it was, uh, not that long ago.

And now it does turn into how many senior people you have, that’s the multiplier. Because they’re trying to take that knowledge and all that data resource that you have, like at a, a rope partner where they’ve prepared really complex problems for years. That data set is amazing if you could get your fingers on it.

Matthew Stead: Uh, yeah, yeah. And I, you know, I completely agree with you, but I just think it’s being oversold and overcooked and overbaked.

Allen Hall: I see it as growing instead of it declining. I don’t think it’s cooling off. I think we’re just at the precipice of [00:17:00] it. As we get better at using some of these AI tools, if we’re gonna build data centers in space, ’cause that’s gonna be the, the linchpin to all this, is if it gets to data centers in space, then we can leverage massive data sets and learn something from them and get better.

Matthew Stead: I love change, but, um, I, I think that’s ri- ridiculous, to be honest. Um, I know we’ve spoken about it a number of times, but data centers in space just seems stupid to me. But, but yeah, going back to your original point, Alan, um, yeah, we, we can definitely do better with you know, more insights around our data and getting more out of our data.

I mean, data is the new oil. You know, we’ve been saying that for the last 10 years. Um, yeah, I’m, I’m full, I’m fully on board with that, but I’m just a little bit of a, a little bit of a negative Nancy on, um, some of these overhype

Allen Hall: The line to connect a new wind project to the U.S. grid has been one of the industry’s most stubborn bottlenecks.

And a new report from Advanced Energy [00:18:00] United drafted by Grid Strategies and the Brattle Group finds that seven major U.S. grid operators have made progress, at least some, on generator interconnection reform since FERC Order 2023 took effect. So that was the order that said we need to fix this interconnect queue problem.

There are just too many people in line and we need to give some ranking to them. But progress on paper has not yet translated into projects moving through the queue faster. And a newer problem is emerging. Fast track interconnection policies at MISO, PJM, and SPP are directing limited system headroom towards, drum roll, utility-affiliated and fossil-heavy resources at the expense of independent clean energy developers.

So the game is being rigged a little bit at the moment where they want to push forward [00:19:00] gas and other fossil fuel type generation in front of solar and wind, which are less costly and quicker to get up and running. This can’t last long, right? E- eventually the people living in, uh, MISO, PJM, and SPP are gonna have a little bit of a revolt on how power prices are gonna bump up accordingly.

Matthew Stead: There’s been numerous other attempts to stifle wind, um, and those numerous other attempts, uh, tend to be overwritten and, uh, ruled out and thrown out in courts. And, um, it, it just seems like this is, well, if that didn’t work, we’ll, we’ll try something else.

Allen Hall: It’s a delay tactic.

Matthew Stead: Yeah, exactly. Then becomes another one.

Well, you know, just wait for that one to be thrown out.

Allen Hall: I don’t know who said the famous saying, time is money, but time is money, and if you can [00:20:00] delay a project from happening, it costs money to sit on the sidelines and you’re, you’re paying interest on a loan or your investors are getting upset because they’re not seeing the returns.

So the easy game in most situations like this is just to drive the schedule to the right, even if it’s by a couple of months. It’s expensive.

Matthew Stead: Yeah. If there’s two things I wish I didn’t know about, the first one is telecommunications and how rubbish it is. I just wish I didn’t, wish I didn’t know about telecommunications and the need for cellular and satellite and blah, blah, blah.

I wish I didn’t know about that. The other one I wish I didn’t know about, because I wish it wasn’t a problem, was just grid connections and grid and networks.

Allen Hall: How bad it is.

Matthew Stead: Yeah. Rosie, if you can jump in, but you know, the New South Wales-South Australian Interconnector Grid, um, is just being energized now.

I don’t know if it’s one or two years late. Um- And they’re trying to recover a billion dollars from the general [00:21:00] public

Rosemary Barnes: Is it only a billion? I thought it, when I looked at the stats, um, it was like near tripling of the, of the project cost

Matthew Stead: My understanding is the government screwed it up or the, uh, the, the operator screwed it up in terms of the transmission lines, and then want, wants to claim it back from the general public ’cause they, they screwed up.

Rosemary Barnes: Yeah. It’s a weird thing ’cause you, you know, it’s like, I think it’s like this everywhere in the world that the, yeah, transmission companies or network companies, they get a regulated rate of return on their, on their project, so they invest. But then it’s like what’s that rate of return for? It’s not money for nothing, right?

It’s for them, you know, like taking on some risk and y- you know, some sorts of things are, are built into that. Um, but it’s kind of like if you, you get that amount approved and then you stuff up your project management so it drags out and takes a lot of money, then you’re also gonna be compensated additionally for having done a bad job with your project [00:22:00] management.

The kinds of delays are not unforeseeable. You know, like I’ve been a project manager in my past. You don’t just make your best case scenario and then kind of just assume that that’s, um, how much it will cost and not, y- you know, not come up with, um, contingency plans for if, uh, if predictable things happen.

It’s not, there’s no like black swan events in here. It’s just, um, you know, things that happen every now and then. And it is one of those like key principles of like delivering on big projects, um, that Ben Slibbert, you know, in that, that book, um, How Big Things Get Done, he goes over and over and over again that you need to keep your project as short as possible ’cause the longer it is, the more like surprises you’ll have along the way and it will cost more.

And I just don’t think that they, like they need to go read that book and then do a better job with their project planning and scenarios.

Allen Hall: You know who’s read that book clearly is, I, I’ll bring up the name, I know it’s gonna cause controversy, [00:23:00] Elon.

Rosemary Barnes: I knew you were gonna say that.

Allen Hall: Well, you know why I say that?

Because there was an interview with him and I was skimming through some nonsense and then this little interview popped up, and he was talking about how quickly they need to get things rolling. And it’s like one year you’re getting s- first year you’re getting started, second year you’re just growing like crazy, and third year is infinity.

And the only way that makes sense is that you’re just pouring every resource on this problem to shorten the schedule That’s it

Rosemary Barnes: You, you do. You have, you have to do the, the, you know, the parts of your project where surprises are gonna happen. Like you can… There are surprises and you know, don’t know what they, they are gonna be.

However, you can guarantee that there will be surprises. Like you, you know going into a years-long project that several things are gonna happen that are, you know, gonna surprise you. And so you can plan for that. And the best planning that you can do is to make sure that once you start actually, you, you know, you’re gonna spend time in planning to, um, get it right, but once you actually start [00:24:00] the phase of your project where delays cost money, then you, you just plan as, do everything you can to keep that as short as possible, and it will be, it’ll be cheaper.

Even if it sounds more expensive, oh, we’ve gotta, you know, pay crews overtime to, you know, do a night shift or something like that, um, you know, you need to consider, consider that because the, there will be delays and they cost. And it’s just, like at this point, maybe 100 years ago you could get away with being surprised by that, but y- you know, like project management has come far enough now that we know, we know this.

It’s just basics.

Allen Hall: But infrastructure projects are tough because they don’t see the revenue on the backside that much sooner. It’s sort of a very flat 3% growth industry Unlike a lot of other things

Rosemary Barnes: But that’s it, like just to contain costs, you have to have a small project.

Allen Hall: They will, but they’ve always historically gotten paid for those overruns and continue to make their 3%.

If there was some sort… Back to Matthew’s point, if there was some sort of, uh, [00:25:00] disincentive to be late, they would hurry, maybe even spend a little bit of their own money, but there would have to be some massive upside, which is the problem, right? They can’t have a massive upside.

Rosemary Barnes: But that’s why I’m s- I’m saying that the situation where costs blow out and they still get…

Like, they get… They make more money by having done a bad job because it costs more. You know, like that is not, it’s not okay.

Allen Hall: Is it more money or just paying the bills that they had when they were building the thing?

Rosemary Barnes: It depends how much we let them get away with, but their preference is to make, just be, “Oh, we could never have known that there would be a flood.”

It’s like, okay, yeah, like, was it like a 1 in 50 years flood or something? So yeah, on average, that particular event wasn’t gonna happen, but there’s probably, you know, like 20 different categories of 1 in 50 year things that could have happened, and if your project lasts for five years, you’re gonna have a few of those.

You just are. You know? It’s not, it’s not bad luck. It’s just like, just normal statistical variation [00:26:00] that y- Yeah, so I, I, I really think it’s important to, um, to not just say, “Oh. Oh, poor you,” ’cause it’s, it always sounds like a sob story. “Oh, a flood. Who could have known?”

Allen Hall: Who could have known it rains?

Rosemary Barnes: Yeah, I mean, I, I don’t know.

Like, I often talk about how people don’t know what, um, engineers do, and we don’t get enough res- respect for, for what we do, and people don’t get it. But I think project managers is, if anything, worse. People don’t respect project management as a, um, a, I don’t know, is it a profession? But, you know, as an ex- ex- field of expertise and don’t, don’t know how much of a difference it makes to have a good one, and also that it is not that hard to be a good project manager.

You just have to actually do it.

Matthew Stead: Can I make a suggestion that actually is the reverse of Darwin theory? We’ve got to come up with a name, but you know, the dumber you are, the more money you make. Also, for the record, um, Elon does have a lot of, um, philosophies and approaches which I do support. The efficiency, automating things after you’ve done them manually, only [00:27:00] doing the bare minimum, you know, all those sorts of things, doing things fast.

Rosemary Barnes: Yeah, there’s a lot, a lot of good product development and engineering that you can learn from Elon, and you do not have to take the, like, weird personal stuff along with it. You are able to pick and choose which aspects you, you learn from.

Allen Hall: But it does take a specific kind of person to weather that storm.

If you wanna play in that sandbox, y- you better be ready because it’ll be hard and fast and not very forgiving. So you just have to know that going in, which can be great, and it can be a great experience, uh, for a lot of engineers, but it isn’t for everyone. As wind energy professionals, staying informed is crucial, and let’s face it, difficult.

That’s why the Uptime Podcast recommends PES Wind Magazine. PES Wind offers a diverse range of in-depth articles and expert insights that dive into the most pressing issues facing our energy future. Whether you’re an [00:28:00]industry veteran or new to wind, PES Wind has the high-quality content you need. Don’t miss out.

Visit peswind.com today. In this quarter’s PES Wind magazine, which you can download at peswind.com, there’s an article from TGS 4C about vessel traffic around offshore wind farms. And this is kind of interesting bec- because they looked at some major wind farms off the coast of the UK, Dogger Bank B, Dogger Bank C, and Sofia.

Uh, and obviously there’s a lot of marine traffic around those, but you don’t really realize the scale and how, uh, it affects the, the traffic on the water. The– When they had looked at these three wind farms, they realized, uh, they had about 860, uh, transits in 2021 around that area, and that went to more than 20,000 by [00:29:00] 2025.

So the amount of economic and commercial activity that was happening around those wind farms exploded. And when you have that many ships in the water, it does change the nature of that area and also how other ships transit through the area, around that area. Uh, it’s an interesting piece because if you look at where those wind farms are, Matthew, th- that’s kind of a narrow stretch in there where there is a lot of ship traffic already.

So y- you create this, uh, artificial barrier for some of the ship traffic, and you’re trying to understand how that is affecting the flow in and out. But I think the, the bigger piece is you can tell how well a development is progressing on offshore wind by looking at the ships and who’s where and when.

Matthew Stead: I think this is interesting topic. Um, I, I– To be honest, I don’t completely get it. Can you explain it to me?

Allen Hall: If I’m an investor in these projects, if I’m the government, if [00:30:00] I’m the, uh, the power company that’s gonna handle the power coming off these sites, I really need to know how it’s going. And the way that I look at it in the States when I look at offshore projects here, ’cause we could do something very similar, who’s out on, on the ocean?

Where are they? What tower are they at? How many towers are running? You can kinda tell that. Are they, are they just doing surveys or are they laying cable? Or is there something more active happening? And where are the ships from? Are they installation vessels? Are they driving monopiles? What’s going on out in the water?

It does give you a really good sense where they are in the project. Kind of back to Rosemary’s point on, on managing big projects, you– schedule is everything You can tell. You can really tell.

Matthew Stead: Thinking about it a different way. So it’s a bit more like shadow monitoring. So it’s just a way of, it’s a way of independently monitoring and checking progress, making sure that there’s transparency as to what’s going on.

Allen Hall: I think there’s a lot of [00:31:00] value in that data set. And as, uh, more operators start to use that data set and more companies start to use that data set globally, uh, they’re gonna be doing offshore projects, I think, differently in, in terms of efficiency. They- they’re learning as they go.

Matthew Stead: Yeah. Isn’t that one of the classical, um, sort of mathematical problems about how to optimize, uh, courier deliveries?

We’ve gotta talk about quantum computing at some point too, so.

Allen Hall: We probably should. But for right now, I need everybody to go to peswind.com and download this quarter’s magazine. A lot of good articles in there, and it’s a great free download. Tons to learn. Go to peswind.com. That wraps up another episode of the Uptime Wind Energy Podcast.

If today’s discussion sparked any questions or ideas, we’d love to hear from you. Reach out to us on LinkedIn. And if you found value in today’s conversation, please leave us a review. It really helps other wind energy professionals discover this [00:32:00] show. For Matthew and Rosemary, I am Allen Hall, and we’ll see you here next week on the Uptime Wind Energy Podcast.

Japan Backs Floating Wind, US Grid Sidelines Clean Energy

Continue Reading

Trending

Copyright © 2022 BreakingClimateChange.com