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Drone Inspection Certification, BladeRobots Goes Solo, U.S. Energy Trends

This week we explore drone inspection certification stirring up Europe and the spin-off of Bladerobots from Vestas. Plus U.S. vs. Australian power trends, wind farms’ community impact, and the potential of AI. And, could single blade turbines solve lightning issues?

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!

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Allen Hall: Rosemary, I don’t know if you have pancakes down in Australia, but in America, it is a big deal. And do you have Eggo’s? Do you know what an Eggo is? An Eggo waffle or an Eggo pancake? Is that a thing? Go to the grocery store or the market, whatever you call it in Australia, and you get a frozen waffle or frozen pancake?

Is that a thing?

Rosemary Barnes: Why would you do that? What? Pancake batter takes about five seconds to throw together from stuff that you’ve definitely got in your pantry and fridge.

Allen Hall: That’s too long, Rosemary. You have not visited

Rosemary Barnes: America lately.

I’m gonna guess it’s full of high fructose corn syrup and other such ridiculousness.

Allen Hall: No. The high fructose corn syrup is poured on it in the form of syrup. See. Eggo is a big brand name in the United States for making frozen waffles. Let go of my eggo. Commercials that have been around forever and also pancakes, but for national pancake day, and this is brilliant, this is a brilliant piece of marketing, Eggo built a pancake shaped house in Tennessee to rent out for national pancake day.

The Eggo House of Pancakes is decorated like a stack of pancakes down to a butter chimney. It has pancake beds, bean bags, syrup fountains, and is stocked with frozen Eggo pancakes. Now, this one single house is in Gatlinburg Tennessee, which is the pancake capital of the South, and you can book a three night stay there in March.

And I’m looking into this. I’m seriously looking into this. It’s part of Eggo’s National Pancake Day. How about that, Rosemary?

Rosemary Barnes: Is it like Shrove, is it Shrove Tuesday? Is that?

Joel Saxum: No, that’s what the high fructose corn syrup’s for.

Allen Hall: You should see this thing. It’s actually quite impressive. They did a good job with it.

It’s like the Oscar Mayer Wienermobile. You can’t miss this thing. Look at Rosemary, I think she got red. Why are you turning red?

Philip Totaro: I’m with her. I don’t know. I don’t get it.

Allen Hall: It’s like the Mr. Peanutmobile. It’s the same sort of thing. Joel, we gotta come up with something like this for StrikeTape.

Joel Saxum: We can do that. I can do that.

Rosemary Barnes: They obviously do have great branding because, like pancakes cost about 20 cents worth of ingredients. There’s like nothing to them. And they’ve managed to sell them pre made in a box. That’s bizarre to me.

Allen Hall: They are delicious.

Joel Saxum: USA .

Rosemary Barnes: Can’t get on board. Sorry. No culture clash.

Joel Saxum: The second chin, that’s Eggo waffles.

Rosemary Barnes: Now there’s a commercial.

Joel Saxum: I work in the wind industry. You know how I make sure the wind doesn’t blow me away every morning? I eat Eggo waffles.

Allen Hall: U. S. electricity generation dipped by roughly 1 percent in 2023 from its record high in 2022. So from roughly 2007 to 2023, generation was only up about 2. 3%, which seems odd based on population growth and things that are happening in the United States. So it’s this report that we’re seeing pop around different places about electricity generation in the United States.

is unusual. Natural gas is the dominant producer or fuel for electricity in the United States, hitting about a little over 40 percent of the total generation due to rosemary. It’s low price and the plants are really efficient. And so the recent, the Biden administration actually canceled a port.

to export natural gas, which then further lower the price. So right for us, but coal Australian coal dipped to a low of less than 16 percent of the share of electricity in the United States down from 50, 50 percent in 2001. If you’re around the United States in 2001, you can see coal trains running everywhere across the United States.

You don’t see that much anymore. So coal is way down, natural gas is way up and renewables are about almost 23 percent of electricity producing in the U. S. Now, when it comes to wind generation, this is really interesting what are the top wind generating states? Obviously Texas, right? That’s an easy choice.

Iowa second, Oklahoma third, Kansas fourth, Illinois fifth, California sixth. That’s way down from where I thought it was. And solar has hit a new high at about almost 6% matching hydro. But obviously solar is growing a lot faster than hydro is going to grow over the next couple of years. Now battery storage, which is another area of interest in the United States.

It, the capacity is booming was 16 gigawatts added in 2023 and another 16 gigawatts expected this year to hit a total of. 32 gigawatts and the battery shift is where batteries are mostly focused at is California and Texas. And we’ll have a story here in a minute, but Texas is going to outpace California on battery storage.

Rosemary, I think that’s an interesting point. And in the United States, coal is dying, natural gas is way up. So the amount of energy produced. The United States is relatively flat, but the generations completely changed over the last roughly 20 years. And I don’t think that’s the same everywhere around the world.

It’s a little, the United States is an oddball, isn’t it, Rosemary?

Rosemary Barnes: Yeah, it’s it’s, I think that the, like the biggest trends in there, the, the replacement of coal with gas is probably nearly 100 percent due to. The amount of domestic gas exploding in that period in the U S so all of a sudden it became very plentiful and incredibly cheap.

And so yeah, that also combine that with the fact that gas is more flexible than coal. Of course, if you would go for a call under the, sorry, you would go for gas over coal in those circumstances. And I think it also does make it a little bit. Harder for renewables to win out just purely on cost like they are elsewhere.

Because if I look I didn’t have time to do any detailed research, but I’ve just quickly pulled up the data for Australia’s generation over the last year. And we’ve got 18. 3 percent from solar, 13. 2 percent from wind, 7. 2 percent from hydro. Yeah, only 4. 8 percent from gas, even though we have, a lot of gas exports here, I think that we’re more free in the export market.

We don’t we, on the east coast, at least of Australia, we don’t reserve any for domestic consumption. It’s just a free for all people, the miners or, yeah, the, Developers can choose to send all of their gas overseas if they want. And so that means that we have the the international price for gas is our price for gas as well, because they’re choosing, where to send it based on cost.

Yeah, on the West Coast, they have a domestic reserve and so their gas is cheap over there and actually I can, I’m on the Open NEM site is a very interesting site to look at Australian electricity information and I can split it out and see Western Australia over the last year 35. 3 percent from gas.

So that’s maybe an example of the difference between when you have cheap gas versus when you don’t have cheap gas because you are. Tied to export prices, which have been high recently. Yeah, so I think that’s really interesting. I know. Yeah, in Australia renewables is growing a lot because of that expensive yeah, the expensive alternatives of coal and gas.

Coal power plants are closing down because renewables are pushing them out. Whereas in the U S that happened a bit earlier that the coal plants closed down, but it’s because gas, it out. Yeah, he really highlights how, when the economics are on the side of the energy transition, things move fast.

And when they are not, then it’s it’s like a wagon stuck in mud or something, you’ve got the government trying to push, push with subsidies and things like that, but it’s tricky. Yeah. And the state of wind energy in the U S I was just listening to a breakdown of it recently.

Someone was doing a review. I think it was Jesse Jenkins. Was doing a review of like the IRA a year on has it actually done the things that it was supposed to and wind is really languishing way below the peak installation and I think it was 2019 and 20 when it peaked. But it’s basically all to do with the, yeah, tax credits and when they have phased in or out, like wind is not standing on its own two feet in the U.

S. like it is in Australia, so it’s.

Joel Saxum: I’ll give you something a little background of that as well when we’re talking the difference between gas and coal. Gas right with the fracking boom. Everybody’s a fracking. That’s where the gas comes from So not only did you have these classical oil fields where this is, you know from 2000 on why it got so cheap Where people think you know, like the Permian Basin in Texas and and something in Oklahoma But all of these oil and gas fields that blew up North Dakota, the Marcella, the Marcella Shale out in, then you have the Appalachians.

That’s all gas. So it’s all, there’s oil mixed in with it, of course. But that’s a lot of where all of our gas capacity comes from, so the amount of rigs out there just pumping gas is one thing, right? But then you have the other side of it, where even if you’re mining coal, now you’ve got to move this stuff.

The logistics of coal mining is a pain. You use rail cars, you’re moving it by trucks to the rail, a lot of times the rail are right into the mines and things like that, yes, but with gas, that’s all pipelines. So once you install that pipeline, you don’t have to pay for the transportation logistics of that fuel anymore.

Some maintenance, of course, yes, but it’s not nearly as what it is, as expensive it is to rail and truck things around the country. Another thing on this report, Rosemary, I wanted to ask you as well is, okay, so one of the problems we know we have in renewables is getting things into the queue, right?

In the United States, solar, you’re hearing solar. People are going to start and a lot of the IPPs are starting to install a lot more solar capacity than they are wind simply because of the economics of it. But the question I have is about battery. So we said 16 gigawatts added in Texas.

Was, or no, 16 gigawatts added in 2023, another 16 gigawatts going to be added in 24, Texas and California dominating. The question is, and this is a technical question because I don’t know it. If you’re already connected to the grid and you’re using the batteries as a storage or a buffer mechanism, is that a completely different thing in the permitting process?

And maybe, I’m not expecting you to know that in the United States, but from a technical standpoint. Are you affecting the grid so much that it would be a new permitting process?

Rosemary Barnes: I know that people are using energy storage as a transmission upgrade or a new transmission alternative. I know examples in both Australia and the US.

In Australia, there’s a mining town or a remote town in the inland New South Wales called Broken Hill. They are connected to the grid, they have a transmission line, but it needs an upgrade. But instead of doing that, they have elected to build a big, they’re building compressed air energy storage.

I can’t remember the numbers off the top of my head, hundreds of megawatts. I’m pretty sure, low hundreds and I think eight or 10 hours storage. And they’re doing that instead of upgrading the transmission, cause obviously a transmission is sized around the peaks, right? The times when you’ve got the most energy.

So it’s not like it’s. Got the same amount of power, it’s not full all the time. So if you have some storage, you can actually just cover the little excess, the bit that your peak would exceed the capacity of the power lines. You can just cover that by battery storage. You don’t need nearly as much as what you might think you would need for even a, like a big regional town.

And the same thing in the U S there’s, like industrial projects that can’t get or industrial projects or there are renewable projects that can’t get enough transmission connection. They’ve got. They can connect up some certain amount of power immediately, or maybe they can’t, but they know that in a few years they will be able to, so what they can do is look at storage to cover the shortfall temporarily, or maybe in the long term.

I can’t remember there was a term for it, but it’s not off grid, but it’s, something similar to off grid in a way, like behind the meter, I don’t know, there was a term for it, but yeah, that, that would be behind the meter, but it’s not, I guess it’s similar to how a house is doing it, but now it would be a whole wind farm or data center or something.

Would be using storage to buffer that and yeah, while they wait for the transmission to catch up, but it’s not just renewables that, it could be sorry, it’s not just battery storage. It could be batteries, but it could also be diesel generators. And in some cases that is actually, they’re finding that’s cheaper, especially when.

They only need it for a year or two.

Joel Saxum: My thought around it was, is I know we have there’s just problems all over the place in the permitting queues. And if a company has capital to deploy and they need to, or want to deploy it this year, it’s if it’s easier just to go and add some battery storage and you have capital deploy.

And it’s in your strategic plan or whatever maybe just go spend your money doing that instead of trying to get new generation online that is, may or may not be able to because of permitting processes.

Philip Totaro: But it is, Joel, it is considered a separate permitting process for a battery. If you have a wind facility and you want to add solar and or storage to it, it’s, you go through a permit.

Again, and in an interconnection study as well.

Joel Saxum: I listened to a lot of ERCOT stuff, and ERCOT’s been calling the last couple years since the winter storm that we had. They’ve been calling for battery storage, and all of a sudden you see all this battery storage pop up. And in my dumb mind, I’m like, man, that was quick.

They called for it, and now it’s here, and it’s online. How did that happen?

Philip Totaro: Yeah, although there’s a bigger reason for that, particularly why California and Texas is because energy traders love to be able to time shift power so that they can price hedge and make Allen, I think we talked about this maybe Joel and Allen and I all talked about this on Newsflash a few weeks ago.

about the energy traders in Europe. This is what energy traders in the U. S. are now trying to do, but they’re leveraging it off of the battery storage that’s being deployed.

Allen Hall: Yeah, because down in Texas, in this year, in 2024, they’re planning to put 6. 4 gigawatts of new batteries on the grid.

And that’ll surpass California, which is only going to put 5. 2 gigawatts out there. And this is a total flip, right? ’cause California has been leading in batteries for a while, but Texas is gonna overcome them very quickly. And again, and as Phil was pointing out, it’s due to the fluctuating prices and they’re playing that difference in price with batteries, which makes sense.

So even though California has been trying to push a lot of batteries, the market is much more acceptable to projects in Texas. So it’s easier to get permitting and get it installed.

Philip Totaro: One last thing, you also see a lot of negative pricing in ERCOT, and nobody likes negative pricing, so they’d rather spend additional capital putting the battery in to time shift the power to when they can actually get a positive price, so for instance, Have your wind produce overnight and then deploy it in the morning between, let’s say, 6 a.

m. and 10 a. m. And, you just made a lot more money than if you had to dump the power overnight because there’s no load. Or insufficient demand.

Allen Hall: So this gets to another discussion that’s been popping up online, which is all electricity going to generation going to become local. And I’ll point out an article that happened in my home state, Nebraska, where they’ve been working on this power line that was going to go to about 250 miles north south in Nebraska and central Nebraska.

It’s called the R Project. So it’s Nebraska Public Powers R Project. It’s supposed to help connect the grid nationally. And, but they haven’t made any move on construction in 12 years after they proposed doing this thing. And they’re running into Ranchers and environmental groups that don’t want the power lines there and private property rights are pretty strong in Nebraska.

So there isn’t a power line. And now they’re running into all kinds of difficulties because the feds and the Nebraska are fighting about those lawsuits. So essentially nothing’s happening. So where that power needs to get delivered, they’re gonna have to figure out a different way. And like we’re talking about with batteries and transmission lines like Rosemary pointed out, they’re not at max capacity all the time.

And as Phil’s pointed out, because of the negative rates, it starts to make sense where you may be putting batteries in your neighborhood to pick up cheaper power, just so you can run during the daytime with some renewable. I think that’s where we’re headed, everybody. The states and the localities are not playing along in some of these.

Transition efforts, and there’s not much you’re gonna do about it.

Philip Totaro: I’m running, right now, off batteries.

Allen Hall: There you go.

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Alright, over in Europe Deutsche Windtechnik drone inspection system received validation from TUV Nord.

Now the article is really in depth about this thing but essentially what it sounds is that Deutsche Windtechnik has a specific drone they use in particular ways. They’re looking at the outside of the blade, obviously, but they’re also doing things around lightning protection systems to, to verify they’re working.

But TUV Norton actually came up with some criteria for doing this and then applied a stamp of approval to the Deutsche Windtechnik’s system for drone inspections. Now, this is completely different than anything in America because it’s what happens in the States is you hire a company like Skyspecs to do it, or you have one of your technicians who’s qualified to fly a drone.

Go out and start taking pictures of your wind turbine. We haven’t seen any effort to put a label or an approval onto a drone system. This seems odd. Maybe it’s a European approach, but when we were at San Diego at ACP MNS. There seems to be a lot of discussion about creating standards for everything.

Everything needs to have an approval, it has to be a standard to it. So there’s uniformity in the industry. If I want to hire a drone inspection, all the drone inspections will meet this criteria, would be one of those efforts. Is this just the beginning of the drone inspection? Approval market is there a rationale to do this?

Do we need this? Is this going to expand into other

areas? I don’t understand the point of this. What are they certifying? That they’re definitely going to capture all of the important information. There’s no way they’re going to be certifying that because I know there’s plenty of well established inspection techniques that definitely miss, miss big, major things.

That’s, basically the entirety of. Blade defect work that I do is, addressing issues that should have been caught, but weren’t so I just, what are they? Certifying.

Rosemary, you’re right. I think they’re certifying that it can catch blade damage and in the scans, and that has enough resolution and whatever the rate that they’re taking photos with, that it will catch those defects of whatever level they, two and above, I would

guess.

There’s no way they’re guaranteeing not to miss anything or something like that. Like that would be really handy if they could say, we’ve inspected it. It’s clear. We guarantee it. I guarantee you that is not what they’re doing. Then there’s no way that anybody is going to inspect your blades and be like, it’s definitely fine.

It’s, that’s not what happens. I

think of what it is they’re walking through the process. They’re developing a, they developed a standard to walk through your processes and see if they’re okay. It’s the same thing as okay, you can have a blade repair company and another blade repair company, but one of them is ISO 9001 approved in their processes.

So in the grand scheme of things, people trust that other company more. They’re like, that one is more legit because they’re certified. This is the first of its kind to my knowledge of certification from a third party certification body of a specific drone solution in the wind industry. I don’t know of any other ones that do it, but because they did this now, I could see others going Oh man, we’ve got to have that because eventually it could turn into this.

Tender process. If you’re not ISO 9000, like if you’re here, you’re going to go torque and tension bolts. You got to be ISO 9001 approved. You got to be on ISNet world. You got to be all these different stamps to your company to say that you have quality HSC process as your quality documentation, your this, that, your other thing.

That’s normal in that ISP space. Gonna, if this is a thing now, it could become this fan. And I know DNV is also working on a standard for image classification for cat categories, right? So there could be these things where it could be X, Y, z, wind farm, or wind. IPP, we’re putting our tender up for the next three years.

If you’re a drone company and you want to come and bid. Give us your, what are they calling this thing? D I N E N, something, 1702, blah blah blah blah blah. They’re gonna say, where’s that stamp, and where’s your classification stamp, to make sure that your stuff is good to go. I could see that happening. But

there, there are countries where They mandate that you have a product certification to be able to sell a wind turbine, for instance.

But there are other countries that don’t mandate it. The companies that go through a process of getting a certification, they do it because they want to be able to sell certain places, and then it’s just a nice to have. In other markets that don’t actually require you to have the product certification to be able to sell

turbans.

Yeah or insurance requires it. Exactly.

That’s what I’m saying though, is if you’re a bank or an insurance, you’re gonna want that stamp more

than not. Some of it’s a capital markets thing too, right? So I dial it back to my oil and gas experience, and there was If you were going offshore with an ROV, when you were gonna try to work for a major, a Chevron, a Shell, a BP, whatever, and you didn’t have that thing UL certified, you weren’t allowed on the rig.

So you immediately dequalified yourself, disqualified yourself from work because your piece of kit, your ROV or instrument or whatever wasn’t certified. They’re not gonna let

you on. I think we’ll have to wait and see how it turns out, because I think in the early term, people are going to be like me and say, what do I get for having this certification?

And currently the answer is nothing, but if assuming that they’re not providing a guarantee that they don’t miss anything, which like, I would honestly, I would take, like a large bet that’s not what’s happening because it’s stupid. But maybe in the future, the, they get the reputation that all of the drone inspection companies that have this certification are also the most accurate.

Maybe then we’ll trust it, but for now like what I haven’t seen or, got the impression that anybody thinks that there’s, like real standout methods and best practices on how you would do things and you can do a checklist approach to say, if it meets all this, then it’s going to be good quality.

I don’t think the industry is there yet. And I don’t think that this, certification process has made such a big leap all in one go. Off on the side quietly, figuring out this large problem without anybody knowing about it. And all of a sudden, yes, now. We know how to tell you if this drone inspection is going to be good without, at the moment you they will give you examples of images that they have taken and defects that you can see and, like the same photo before and after damage, you get stuff like that to qualitatively get the.

Trust in the system that it’s doing what you want. And I personally would still get more trust from having seen that from then from having a stamp from Tufnord. I, like I, I don’t trust this product yet. But that may change as time

goes. I agree with you, Rosemary and I can go back to the number the number of the certification.

Now, this shows you it’s early in life. It’s TN-P-V01-001. That means we’re pretty early.

Rosemary Barnes: Why couldn’t you remember that, Joel? It really sticks in your mind.

Allen Hall: Rolls right off the tongue.

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So sticking on the robot. Drone theme here Vestas is standing up Blade Robots as a standalone company. And we saw this, Joel, over in Copenhagen. Wind Europe. Wind Europe. Yeah, sure. It really cool product. What Blade Robot is, Phil, I don’t think you saw this up close, but it, the blade goes horizontal.

And they drop a robot on it, and then it repairs the leading edge. That’s essentially what the robot does.

Philip Totaro: Yeah, I’ve seen these before.

Allen Hall: Yeah, it’s an interesting piece of hardware. Obviously, it’s a Vestas outgrowth. Vestas makes turbines. They know there’s leading edge erosion problems. They know it needs to get fixed.

So they created their own little company called Blade Robots to go do this. They installed a couple of people at the head of the company. Michael Svensson, who was formerly of Ventus Wind Services, and a new chairman, Johnny Thompson, who was co CEO of MHI Vestas Offshore Wind, Joel. So that’s where the MHI Vestas Offshore Wind people went.

Joel Saxum: Blade Robots?

Allen Hall: Blade Robots has attracted some investment from Skagen. And Vestas Ventures holds a majority stakes still in that effort, but I think, again, the whole Deutsche Windtechnik, getting the certification, made me think about this Blade Robots piece because it’s in the same part of the world.

Are we going to start seeing some standards pushed out for leading edge repair and some of the other things that are happening in the robot world, because as Rosemary’s kind of pointed out, the consistency is the key. And do we have minimum performance guarantees or do we need to have some standards so that not every operator in the world has to go vet the system?

That’s where, a DMV or certification body would step into, right? That’s the whole point of them is to get rid of every operator having to repeat the same qualification tests. Is that where we’re headed? And is that something that Vestas would have a leg up on?

Joel Saxum: I would say maybe down the road, but that, if you’re talking robotics, blade repair, robotic LEP, these kind of things.

We’re way too early for it. It’s too immature. There’s really only three and a half companies playing in that space. One doing it full on, right? So it’s just, it’s so early and it’s such an immature technology set. Now, it’s going to, I fully believe, this is my opinion, I guess as I have an Aerones sweatshirt on, that’s what I’m saying, I fully believe that robotics are the future of wind turbine maintenance, and I think that there’s going to become more and more solutions that will be, right now we’re talking LEP, I think there will become, I talked to someone the other day about scarf repairs, and they’re like, there’s no way, they can’t do that, I’m like, man, it’s actually pretty simple to do with AI vision things, how deep you are, and that’s, I can code that’s not that hard so I think that we’re just talking blades I think there’s going to start to be more torque and tensioning tools that are roboticized and some other things.

But that’s just me so I think in the future, yes, we’ll run into these things where we’re going to have some standards that will need to come out. But at this point it’s so early.

Allen Hall: It’s definitely early. I’m not sure if robots are the future, but it appears that way at the moment.

Joel Saxum: Have you seen Terminator?

Allen Hall: I have. I believe that children are our future. Teach them well and let them lead the way.

Joel Saxum: Yeah, send them to robotic school so they can have a good job in the future.

Rosemary Barnes: You can get them the Elon Musk brain chip and help them become a robot of the future.

Allen Hall: I could use one of those right now.

Joel Saxum: The CEO of NVIDIA, though, just said that you don’t have to teach kids to code because AI is going to do it for them now.

Rosemary Barnes: I, can I add a personal anecdote for that? Because So I during my PhD days, I felt that knowing Python scripting in Python would be a useful addition to my repertoire.

I am like such a hack at coding. I can do it, but I suck. And so I’m like, I’m going to learn Python. And I bought a book, like a. And a week later I gave up on that and just hacked my way through with I think I used MATLAB code and I learned the, yeah, APDL for for ANSYS as well.

They’re proprietary scripting language. I did it mostly in that. Anyway, fast forward to recently I needed to, for my consulting work, I needed to get access to like literally thousands of zip files on this data repository of energy data. And extract them all and get each CSV file into a, an individual page in an Excel spreadsheet.

And I have started asking ChatGPT to help me with coding. And so I’m like, ChatGPT, could you help me write a write a macro for for Excel to do this and ChatGPT is you don’t want to do that. You should write a Python script. And I’m like, no ChatGPT. I know that Python is really hard and too hard for me.

So let’s do the, let’s do the macro. What would, you stupid robot. And and so we started writing the macro and it got, it was so impossible with all these permissions. Anything I gave up on my, all right, I asked my brother, who’s like a computer science guy. And he’s Oh, you should do a Python script.

It’ll be easier to start from scratch. ChatGPT had me up and running in half an hour. I had my Python script working and was troubleshooting debugging, everything. It worked. So yeah, ChatGPT is the future for coding, I would say. And I might’ve said a month or two ago, I might’ve said as if you can avoid learning to code.

But now I think, yeah, it’s not going to be about learning to code. It’s going to be about teaching kids to think like algorithmically so that they can oversee robots to code. And I know a lot of my, a lot of my friends that do code professionally say I’ve gotten so lazy. Like I’m never on GitHub anymore.

I’m just asking ChatGPT because I know it’ll know the answer. And it’s crazy how good it is at it actually.

Joel Saxum: Last summer, I heard someone say Python. I can barely put a night crawler on a fishing hook.

Allen Hall: I don’t have, where am I supposed to go with that? Like that. There’s no out

to that.

Rosemary Barnes: That can be just the end. Then the podcast just finishes silence after that. .

Joel Saxum: The interesting thing here in this blade robot though is scag and invested them. Because Skagen is a blade repair company, and they’re the first blade repair company that I’ve seen as an ISP that said, I’m going to invest in technology that’s going to replace our technicians.

Allen Hall: No, it won’t replace technicians, just make them more efficient.

Philip Totaro: Compliment the technicians.

Rosemary Barnes: It just amplifies it. It’s just a productivity enhancement. Fine. Like maybe, like with my work, I use ChatGPT a lot and I could have hired a full time grad to train to do all this stuff, except that I couldn’t have, because I don’t have the money to do that.

My choice wasn’t between a human person to do this or ChatGPT. My choice was between doing less work or doing more with ChatGPT. And actually my company will grow faster because of that and because of using it. And then I’ll be more likely to hire someone. And I just think.

Like maybe for some big corporations, it will at some point be a matter of, oh, we actually need less people to do this layoffs because we’ve got chat GPT and AI filling that role. But I think overall it’s really a productivity enhancement. That’s not so different to other productivity enhancements we’ve had in the past.

Allen Hall: You gotta write this date down because Rosemary and Elon Musk agree on something.

Rosemary Barnes: And we agree on a lot of things. If he’s talking about energy, I not 99 percent of the time, I agree with him on energy. And I think that he is like an energy system genius. But 99 percent of the time when he talks about things that aren’t energy, I do not care to listen to him at all. Yeah.

Allen Hall: Brain implants. Where does it, where’s the limit at Rosemary? Now what things are in and what things are out? Should we should discuss that. What’s in? What’s out?

Joel Saxum: Where do you draw the line?

Allen Hall: Where, yeah, where is that line? We need to know.

Rosemary Barnes: I bet that brain chips are inevitable, but it doesn’t mean that we have to feel comfortable about it.

Joel Saxum: I’ll volunteer for it.

Allen Hall: That’s an engineering person saying that.

Rosemary Barnes: I reckon, and I hope that it doesn’t happen in my lifetime because, and probably all of us, anybody that has gained, a certain advantage in their professional world by learning things fast, Once everyone’s got brain chips, then we’re no longer gonna have that advantage and we’re, what’s the difference gonna be between, we’ll be doing a, a lower lower enumerated job in the future if everybody is just as capable as anybody else at learning things.

Philip Totaro: I’ll tell you what, I’m waiting for the day when I can download my consciousness into AI. And then I will basically live forever.

Allen Hall: No one wants my consciousness.

Joel Saxum: As long as my chip doesn’t run on Power BI, I’m alright. I don’t need the graphs churning on Power BI in there. Give me something else.

Allen Hall: Rosemary has the question of the week. So rosemary, go ahead.

Rosemary Barnes: On my Engineering with Rosie Patreon. We have a discord server and somebody has written in a question in regards to lightning and wind turbines, would a single blade turbine be superior in that it can be stopped in a six o’clock position.

So blade hanging down the bottom. Or a turbine with two blades stopped at three and nine o’clock when high electrical potential is detected. So I’m guessing that his idea is that, instead of having a blade right up making the wind turbine even taller, you put the blades in lower positions and avoid being so high and avoid getting struck by lightning.

So I thought that was the perfect question for you guys being the lightning experts that you are, lightning and wind energy experts. What do you think? Is this an idea?

Allen Hall: Oh, it’s an idea, but there’s a better idea, which is just to keep the turbine rotating and making money. That’s the best idea. And the way we do that is to make the LPS system a lot better than it is right now.

So there’s been a lot of effort for all around the world to stop turbines. That quite a bit where if there’s a thunderstorm around, they believe they’re putting in the. Putting the blades as low as they can go is the right solution. But it doesn’t really change the fact that they’re going to get struck by lightning.

It really doesn’t move the needle much. So yeah, you probably could change it a little bit. It looks like the data from rotating versus non rotating is just a couple of percentage points. It’s not like 30%, 40 percent less. The real magic here is let’s just make an LPS system that works. Now, Rosemary, you were sitting at the lightning desk at a blade manufacturer.

Is it possible? It seems like to us, this is us, Weather Guard saying we, we’ve been able to do the magic. So we’ve stopped pretty much lightning damage in every blade we’ve been on. The OEMs have not. Why?

Rosemary Barnes: I can’t answer that. I will say though, that I would, it, lightning protection is such a nightmare , when you’re developing any other part of a blade, and you have to worry about.

Doing what the lightning people tell you to do, and it’s not very much of a discussion, like nearly every other requirement of a blade, it’s a bit of a two way discussion, if I needed to when I’m, putting my de icing system in a blade, if I needed to drill a hole somewhere through some structural component.

I’d go talk with, the chief engineer of structural design and he’d say, Oh, it’s that’s a really bad place to put it. If you need a hole can you put it, off to the side away from the lane, main laminate, or can make two holes of this smaller diameter instead of that one, like it’s a.

He’ll tell you what are the reasons why he’s saying we can’t do that and help you find a solution. Whereas with lightning, it was much more, Oh, we actually don’t a hundred percent know why. We just know that, when this, we’ve had a design that looks like that in the past, it was really bad.

So we never do that again, but we’re not a hundred percent sure why. And then. Another complicating factor is that the simulations are so freaking expensive. You don’t run a whole bunch of computational simulations for lightning. You try to run one and, for a really complex design, you might plan on two and hope that you don’t have to do three or more, but it’s not like you’re trying something, tweaking it, trying something, tweaking it like you can with structural design with a finite element model, you can run, so many different.

Goes of it, they’re also not super accurate, as you’re probably aware, just because you have a simulation that shows that lightning damage isn’t going to happen. It doesn’t mean that you’re not going to see it.

Joel Saxum: I can see, so the user’s question I completely understand the concept, right?

Let’s just try to keep those tips up from being high. Let’s keep them low. I get that. However, at the end of the day, even if you have three and nine o’clock, you’re still the highest thing out there. It’s, you’re still going to get hit. That’s gonna happen no matter what. And if you look at the IEC standard, how they test wind turbine LPS systems.

It’s a test where you have you’re to the floor as, and the floor becomes the plane of the cloud. So yeah, you test it, you test at 90 degrees to the floor, 60 degrees to the floor, 30. 30 and 10 and it is and when you get down to that 10 degree spot It’s really hard to get LPS attachments properly how you want them. And so if you went down to a zero flat plane That whole yeah, it’s gonna be really actually would probably to be honest with You’d probably be worse off if you had a three o’clock nine o’clock twin blade or wrong lightning attachments if it was stopped in a storm.

Allen Hall: You’d be better off pointing it straight up in the air and have an LPS system that works.

Rosemary Barnes: Yeah. Wow.

Allen Hall: But that’s a good question from Patreon. And everybody needs to reach out on, get to Rosemary’s discord server. I didn’t, Rosemary, I didn’t even realize you had a discord server. I don’t, I’m not a part of the discord server. I feel like I’m an outie, not an innie.

Rosemary Barnes: It’s because you’re not a Patreon. You have to join us for Patreons only. Patreons are that support the Engineering with Rosie YouTube channel and help support this in-depth engineering analysis.

Allen Hall: How would I do that? How would I join the Rosemary Patreon group?

Joel Saxum: I’m already in the Rosemary fan club.

Rosemary Barnes: You’re not in the official fan club. This is the fan club.

Allen Hall: Nor will you be.

Rosemary Barnes: www.patreon.com/engineeringwithrosie, but it is pretty fun. There’s about 200 of us now in the group and yeah, so there’s, yeah, there’s quite often there’s some fun, fun discussion on the discord and on Patreon and yeah, you get early access to videos and it’s really helpful for me because, such a great group of people that really have in depth knowledge about a lot of topics, so I’m often getting, amazing feedback from that group.

So yeah, feel free to join.

Joel Saxum: All right. Our Wind Farm of the Week this week is Locket Wind. It’s located in Wilbarger County, Texas. So the project generates 184 megawatts of onshore wind power, which is enough electricity to power more than 56, 000 homes. It became commercial in July 2019. So this is an Orsted project.

But Orsted’s basically vehicle for developing in the States Lincoln Clean Energy is who developed it. There’s 75 GE 2. 5 machines out here. What I want to highlight this week on this one is something we don’t normally dive into. Floating around the internet, I did find one of their application to the Vernon County Independent School Board while they were in the process of building this wind farm.

In Texas, people that don’t know this, the school boards actually have a lot of power. At the municipal level, they can influence county boards and decisions that happens around there because of a lot of the money that comes in. But there’s a, it’s a hundred and some odd page document, but I pulled a couple of cool things out of it.

So in its applicant, I’m going to read from it. So in its application, the applicant has, and so the applicant, they’re talking about Orsted, they committed to six new qualifying jobs, and they set the minimum salary for them, and that minimum salary Is on section one E is pays at least a hundred and ten percent of the county average weekly wage for manufacturing jobs in the county where it’s located.

So that’s pretty cool. Wind farm comes into town and they’re legally guaranteeing that they’re going to pay more on that wind farm than the average wage in the town. They also have things in here for how many hours of work that the person won’t be transferred from area to area, that they will be working and living in that county.

Or not necessarily living, but they’ll be working in that county. Not created to replace previous employees. It even goes as far as stipulating that they will have health care benefits and all kinds of stuff. Another one that they put in here is that they will, the revenue gains will be realized by the school district in support of this finding the some independent experts there.

Where they’re going to initially add 180 million to the tax base in the county for that one wind farm. When Orsted built this thing, 200 construction workers were anticipated at the peak of construction. And then they had a minimum of, they have a minimum of 6 permanent jobs on this site. Some cool documentation, you can find it if you want to Google it, but shows the value that wind farms Bring to the local communities.

So Locket wind from Orsted in North Texas. You are a wind farm of the week.

Allen Hall: That’s going to do it for this week’s uptime wind energy podcast. Thanks for listening. Please give us a five star rating on your podcast platform and subscribe in the show notes below to uptime tech news, our weekly newsletter, and check out Rosemary’s YouTube channel engineering with Rosie, and we’ll see you here next week on the uptime wind energy podcast.

Drone Inspection Certification, BladeRobots Goes Solo, U.S. Energy Trends

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Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage

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Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage

This exclusive article originally appeared in PES Wind 4 – 2025 with the title, Operations take center stage in wind’s next chapter. It was written by Allen Hall and other members of the WeatherGuard Lightning Tech team.

As aging fleets, shrinking margins, and new policies reshape the wind sector, wind energy operations are in the spotlight. The industry’s next chapter will be defined not by capacity growth, but by operational excellence, where integrated, predictive maintenance turns data into decisions and reliability into profit.

Wind farm operations are undergoing a fundamental transformation. After hosting hundreds of conversations on the Uptime Wind Energy Podcast, I’ve witnessed a clear pattern: the most successful operators are abandoning reactive maintenance in favor of integrated, predictive strategies. This shift isn’t just about adopting new technologies; it’s about fundamentally rethinking how we manage aging assets in an era of tightening margins and expanding responsibilities.

The evidence was overwhelming at this year’s SkySpecs Customer Forum, where representatives from over 75% of US installed wind capacity gathered to share experiences and strategies. The consensus was clear: those who integrate monitoring, inspection, and repair into a cohesive operational strategy are achieving dramatic improvements in reliability and profitability.

Takeaway: These options have been available to wind energy operations for years; now, adoption is critical.

Why traditional approaches to wind farm operations are failing

Today’s wind operators face an unprecedented convergence of challenges. Fleets installed during the 2010-2015 boom are aging in unexpected ways, revealing design vulnerabilities no one anticipated. Meanwhile, the support infrastructure is crumbling; spare parts have become scarce, OEM support is limited, and insurance companies are tightening coverage just when operators need them most.

The situation is particularly acute following recent policy changes. The One Big Beautiful Bill in the United States has fundamentally altered the economic landscape. PTC farming is no longer viable; turbines must run longer and more reliably than ever before. Engineering teams, already stretched thin, are being asked to manage not just wind assets but solar and battery storage as well. The old playbook simply doesn’t work anymore.

Consider the scope of just one challenge: polyester blade failures. During our podcast conversation with Edo Kuipers of We4Ce, we learned that an estimated 30,000 to 40,000 blades worldwide are experiencing root bushing issues. ‘After a while, blades are simply flying off,’ Kuipers explained. The financial impact of a single blade failure can exceed €300,000 when you factor in replacement costs, lost production, and crane mobilization. Yet innovative repair solutions, like the one developed by We4Ce and CNC Onsite, can address the same problem for €40,000 if caught early. This pattern repeats across every major component. Gearbox failures that once required complete replacement can now be predicted months in advance. Lightning damage that previously caused catastrophic failures can be prevented with inexpensive upgrades and real-time monitoring. All these solutions are based on the principle that predicted maintenance is better than an expensive surprise.

Seeing problems before they happeny, and potential risks

The transformation begins with visibility. Modern monitoring systems reveal problems that traditional methods miss entirely. Eric van Genuchten of Sensing360 shared an eye-opening statistic on our podcast: ‘In planetary gearbox failures, they get 90%, so there’s still 10% of failures they cannot detect.’ That missing 10% represents the catastrophic failures that destroy budgets and production targets. Advanced monitoring technologies are filling these gaps. Sensing360’s fiber optic sensors, for example, detect minute deformations in steel components, revealing load imbalances and fatigue progression invisible to traditional monitoring. ‘We integrate our sensors in steel and make rotating equipment smarter,’ van Genuchten explained.

Other companies are deploying acoustic systems to identify blade delamination, oil analysis for gearbox health, and electrical signature analysis for generator issues. Each technology adds a piece to the puzzle, but the real value comes from integration. The impact of load monitoring alone can be transformative.

As van Genuchten explained, ‘Twenty percent more loading on a gearbox or on a bearing is half of your life. The other way around, twenty percent less loading is double your life.’ With proper monitoring, operators can optimize load distribution across their fleet, extending component life while maximizing production.

But monitoring without action is just expensive data collection. The most successful operators are those who’ve learned to translate sensor data into operational decisions. This requires not just technology but organizational change, breaking down silos between monitoring, maintenance, and management teams.

In Wind Energy Operations, Early intervention makes the million-dollar difference

The economics of early intervention are compelling across every component type. The blade root bushing example from We4Ce illustrates this perfectly. With their solution, early detection means replacing just 24-30 bushings in about 24 hours of drilling work. Wait, and you’re looking at 60+ bushings and 60 hours of work. Early detection doesn’t just prevent catastrophic failure; it makes repairs faster, cheaper, and more reliable.

This principle extends throughout the turbine. Early-stage bearing damage can be addressed through targeted lubrication or minor adjustments. Incipient electrical issues can be resolved with cleaning or connection tightening. Small blade surface cracks can be repaired in a few hours before they propagate into structural damage requiring weeks of work.

Leading operators are implementing tiered response protocols based on monitoring data. Critical issues trigger immediate intervention. Developing problems are scheduled for the next maintenance window. Minor issues are monitored and addressed during routine service. This systematic approach reduces both emergency repairs and unnecessary maintenance, optimizing resource allocation across the fleet.

Turning information into action

While monitoring generates data, platforms like SkySpecs’ Horizon transform that data into operational intelligence. Josh Goryl, SkySpecs’ Chief Revenue Officer, explained their evolution at the recent Customer Forum: ‘I think where we can help our customers is getting all that data into one place.

The game-changer is integration across data types. The company is working to combine performance data with CMS data to provide valuable insights into turbine health. This approach has been informed by operators across the world, who’ve discovered that integrated platforms deliver insights that siloed data can’t.

The platform approach also addresses the reality of shrinking engineering teams managing expanding portfolios. As Goryl noted, many wind engineers are now responsible for solar and battery storage assets as well. One platform managing multiple technologies through a unified interface becomes essential for operational efficiency.

The Integration Imperative for Wind Farm Operations

The most successful operators aren’t just adopting individual technologies; they’re integrating monitoring, inspection, and repair into a seamless operational system. This integration operates at multiple levels.

At the technical level, data from various monitoring systems feeds into unified platforms that provide comprehensive asset visibility. These platforms don’t just display data; they analyze patterns, predict failures, and generate work orders.

At the organizational level, integration means breaking down barriers between departments. This cross-functional collaboration transforms O&M from a cost center into a value driver. Building your improvement roadmap For operators ready to enhance their O&M approach, the path forward involves several key steps:

Assessing the Current State of your Wind Energy Operations

Document your maintenance costs, failure rates, and downtime patterns. Identify which problems consume the most resources and which assets are most critical to your wind farm operations.

Start with targeted pilots Rather than attempting wholesale transformation, begin with focused initiatives targeting your biggest pain points. Whether it’s blade monitoring, gearbox sensors, or repair innovations, starting with your largest issue will help you see the biggest benefit.

• Invest in integration, not just technology: the most sophisticated monitoring system is worthless if its data isn’t acted upon. Ensure your organization has the processes and culture to transform data into decisions – this is the first step to profitability in your wind farm operations.

Build partnerships, not just contracts: look for technology providers and service companies willing to share knowledge, not just deliver services. The goal is building capability, not dependency.

• Measure and iterate: track the impact of each initiative on your key performance indicators. Use lessons learned to refine your approach and guide future investments.

The competitive advantage

The wind industry has reached an inflection point. With increasingly large and complex turbines, monitoring needs to adapt with it. The era of flying blind is over.

In an industry where margins continue to compress and competition intensifies, operational excellence has become a key differentiator. Those who master the integration of monitoring, inspection, and repair will thrive. Those who cling to reactive maintenance face escalating costs and declining competitiveness.

The technology exists. The business case is proven. The early adopters are already reaping the benefits. The question isn’t whether to transform your O&M approach, but how quickly you can adapt to this new reality. In the race to operational excellence, the winners will be those who act decisively to embrace the efficiency revolution reshaping wind operations.

Unless otherwise noted, images here are from We4C Rotorblade Specialist.

Wind Industry Operations: In Wind's Next Chapter, Operations take center stage

Contact us for help understanding your lightning damage, future risks, and how to get more uptime from your equipment.

Download the full article from PES Wind here

Find a practical guide to solving lightning problems and filing better insurance claims here

Wind Industry Operations: In Wind's Next Chapter, Operations take center stage

Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage

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BladeBUG Tackles Serial Blade Defects with Robotics

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BladeBUG Tackles Serial Blade Defects with Robotics

Chris Cieslak, CEO of BladeBug, joins the show to discuss how their walking robot is making ultrasonic blade inspections faster and more accessible. They cover new horizontal scanning capabilities for lay down yards, blade root inspections for bushing defects, and plans to expand into North America in 2026.

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

Welcome to Uptime Spotlight, shining Light on Wind. Energy’s brightest innovators. This is the Progress Powering Tomorrow.

Allen Hall: Chris, welcome back to the show.

Chris Cieslak: It’s great to be back. Thank you very much for having me on again.

Allen Hall: It’s great to see you in person, and a lot has been happening at Blade Bugs since the last time I saw Blade Bug in person. Yeah, the robot. It looks a lot different and it has really new capabilities.

Chris Cieslak: So we’ve continued to develop our ultrasonic, non-destructive testing capabilities of the blade bug robot.

Um, but what we’ve now added to its capabilities is to do horizontal blade scans as well. So we’re able to do blades that are in lay down yards or blades that have come down for inspections as well as up tower. So we can do up tower, down tower inspections. We’re trying to capture. I guess the opportunity to inspect blades after transportation when they get delivered to site, to look [00:01:00] for any transport damage or anything that might have been missed in the factory inspections.

And then we can do subsequent installation inspections as well to make sure there’s no mishandling damage on those blades. So yeah, we’ve been just refining what we can do with the NDT side of things and improving its capabilities

Joel Saxum: was that need driven from like market response and people say, Hey, we need, we need.

We like the blade blood product. We like what you’re doing, but we need it here. Or do you guys just say like, Hey, this is the next, this is the next thing we can do. Why not?

Chris Cieslak: It was very much market response. We had a lot of inquiries this year from, um, OEMs, blade manufacturers across the board with issues within their blades that need to be inspected on the ground, up the tap, any which way they can.

There there was no, um, rhyme or reason, which was better, but the fact that he wanted to improve the ability of it horizontally has led the. Sort of modifications that you’ve seen and now we’re doing like down tower, right? Blade scans. Yeah. A really fast breed. So

Joel Saxum: I think the, the important thing there is too is that because of the way the robot is built [00:02:00] now, when you see NDT in a factory, it’s this robot rolls along this perfectly flat concrete floor and it does this and it does that.

But the way the robot is built, if a blade is sitting in a chair trailing edge up, or if it’s flap wise, any which way the robot can adapt to, right? And the idea is. We, we looked at it today and kind of the new cage and the new things you have around it with all the different encoders and for the heads and everything is you can collect data however is needed.

If it’s rasterized, if there’s a vector, if there’s a line, if we go down a bond line, if we need to scan a two foot wide path down the middle of the top of the spa cap, we can do all those different things and all kinds of orientations. That’s a fantastic capability.

Chris Cieslak: Yeah, absolutely. And it, that’s again for the market needs.

So we are able to scan maybe a meter wide in one sort of cord wise. Pass of that probe whilst walking in the span-wise direction. So we’re able to do that raster scan at various spacing. So if you’ve got a defect that you wanna find that maximum 20 mil, we’ll just have a 20 mil step [00:03:00] size between each scan.

If you’ve got a bigger tolerance, we can have 50 mil, a hundred mil it, it’s so tuneable and it removes any of the variability that you get from a human to human operator doing that scanning. And this is all about. Repeatable, consistent high quality data that you can then use to make real informed decisions about the state of those blades and act upon it.

So this is not about, um, an alternative to humans. It’s just a better, it’s just an evolution of how humans do it. We can just do it really quick and it’s probably, we, we say it’s like six times faster than a human, but actually we’re 10 times faster. We don’t need to do any of the mapping out of the blade, but it’s all encoded all that data.

We know where the robot is as we walk. That’s all captured. And then you end up with really. Consistent data. It doesn’t matter who’s operating a robot, the robot will have those settings preset and you just walk down the blade, get that data, and then our subject matter experts, they’re offline, you know, they are in their offices, warm, cozy offices, reviewing data from multiple sources of robots.

And it’s about, you know, improving that [00:04:00] efficiency of getting that report out to the customer and letting ’em know what’s wrong with their blades, actually,

Allen Hall: because that’s always been the drawback of, with NDT. Is that I think the engineers have always wanted to go do it. There’s been crush core transportation damage, which is sometimes hard to see.

You can maybe see a little bit of a wobble on the blade service, but you’re not sure what’s underneath. Bond line’s always an issue for engineering, but the cost to take a person, fly them out to look at a spot on a blade is really expensive, especially someone who is qualified. Yeah, so the, the difference now with play bug is you can have the technology to do the scan.

Much faster and do a lot of blades, which is what the de market demand is right now to do a lot of blades simultaneously and get the same level of data by the review, by the same expert just sitting somewhere else.

Chris Cieslak: Absolutely.

Joel Saxum: I think that the quality of data is a, it’s something to touch on here because when you send someone out to the field, it’s like if, if, if I go, if I go to the wall here and you go to the wall here and we both take a paintbrush, we paint a little bit [00:05:00] different, you’re probably gonna be better.

You’re gonna be able to reach higher spots than I can.

Allen Hall: This is true.

Joel Saxum: That’s true. It’s the same thing with like an NDT process. Now you’re taking the variability of the technician out of it as well. So the data quality collection at the source, that’s what played bug ducts.

Allen Hall: Yeah,

Joel Saxum: that’s the robotic processes.

That is making sure that if I scan this, whatever it may be, LM 48.7 and I do another one and another one and another one, I’m gonna get a consistent set of quality data and then it’s goes to analysis. We can make real decisions off.

Allen Hall: Well, I, I think in today’s world now, especially with transportation damage and warranties, that they’re trying to pick up a lot of things at two years in that they could have picked up free installation.

Yeah. Or lifting of the blades. That world is changing very rapidly. I think a lot of operators are getting smarter about this, but they haven’t thought about where do we go find the tool.

Speaker: Yeah.

Allen Hall: And, and I know Joel knows that, Hey, it, it’s Chris at Blade Bug. You need to call him and get to the technology.

But I think for a lot of [00:06:00] operators around the world, they haven’t thought about the cost They’re paying the warranty costs, they’re paying the insurance costs they’re paying because they don’t have the set of data. And it’s not tremendously expensive to go do. But now the capability is here. What is the market saying?

Is it, is it coming back to you now and saying, okay, let’s go. We gotta, we gotta mobilize. We need 10 of these blade bugs out here to go, go take a scan. Where, where, where are we at today?

Chris Cieslak: We’ve hads. Validation this year that this is needed. And it’s a case of we just need to be around for when they come back round for that because the, the issues that we’re looking for, you know, it solves the problem of these new big 80 a hundred meter plus blades that have issues, which shouldn’t.

Frankly exist like process manufacturer issues, but they are there. They need to be investigated. If you’re an asset only, you wanna know that. Do I have a blade that’s likely to fail compared to one which is, which is okay? And sort of focus on that and not essentially remove any uncertainty or worry that you have about your assets.

’cause you can see other [00:07:00] turbine blades falling. Um, so we are trying to solve that problem. But at the same time, end of warranty claims, if you’re gonna be taken over these blades and doing the maintenance yourself, you wanna know that what you are being given. It hasn’t gotten any nasties lurking inside that’s gonna bite you.

Joel Saxum: Yeah.

Chris Cieslak: Very expensively in a few years down the line. And so you wanna be able to, you know, tick a box, go, actually these are fine. Well actually these are problems. I, you need to give me some money so I can perform remedial work on these blades. And then you end of life, you know, how hard have they lived?

Can you do an assessment to go, actually you can sweat these assets for longer. So we, we kind of see ourselves being, you know, useful right now for the new blades, but actually throughout the value chain of a life of a blade. People need to start seeing that NDT ultrasonic being one of them. We are working on other forms of NDT as well, but there are ways of using it to just really remove a lot of uncertainty and potential risk for that.

You’re gonna end up paying through the, you know, through the, the roof wall because you’ve underestimated something or you’ve missed something, which you could have captured with a, with a quick inspection.

Joel Saxum: To [00:08:00] me, NDT has been floating around there, but it just hasn’t been as accessible or easy. The knowledge hasn’t been there about it, but the what it can do for an operator.

In de-risking their fleet is amazing. They just need to understand it and know it. But you guys with the robotic technology to me, are bringing NDT to the masses

Chris Cieslak: Yeah.

Joel Saxum: In a way that hasn’t been able to be done, done before

Chris Cieslak: that. And that that’s, we, we are trying to really just be able to roll it out at a way that you’re not limited to those limited experts in the composite NDT world.

So we wanna work with them, with the C-N-C-C-I-C NDTs of this world because they are the expertise in composite. So being able to interpret those, those scams. Is not a quick thing to become proficient at. So we are like, okay, let’s work with these people, but let’s give them the best quality data, consistent data that we possibly can and let’s remove those barriers of those limited people so we can roll it out to the masses.

Yeah, and we are that sort of next level of information where it isn’t just seen as like a nice to have, it’s like an essential to have, but just how [00:09:00] we see it now. It’s not NDT is no longer like, it’s the last thing that we would look at. It should be just part of the drones. It should inspection, be part of the internal crawlers regimes.

Yeah, it’s just part of it. ’cause there isn’t one type of inspection that ticks all the boxes. There isn’t silver bullet of NDT. And so it’s just making sure that you use the right system for the right inspection type. And so it’s complementary to drones, it’s complimentary to the internal drones, uh, crawlers.

It’s just the next level to give you certainty. Remove any, you know, if you see something indicated on a a on a photograph. That doesn’t tell you the true picture of what’s going on with the structure. So this is really about, okay, I’ve got an indication of something there. Let’s find out what that really is.

And then with that information you can go, right, I know a repair schedule is gonna take this long. The downtime of that turbine’s gonna be this long and you can plan it in. ’cause everyone’s already got limited budgets, which I think why NDT hasn’t taken off as it should have done because nobody’s got money for more inspections.

Right. Even though there is a money saving to be had long term, everyone is fighting [00:10:00] fires and you know, they’ve really got a limited inspection budget. Drone prices or drone inspections have come down. It’s sort, sort of rise to the bottom. But with that next value add to really add certainty to what you’re trying to inspect without, you know, you go to do a day repair and it ends up being three months or something like, well

Allen Hall: that’s the lightning,

Joel Saxum: right?

Allen Hall: Yeah. Lightning is the, the one case where every time you start to scarf. The exterior of the blade, you’re not sure how deep that’s going and how expensive it is. Yeah, and it always amazes me when we talk to a customer and they’re started like, well, you know, it’s gonna be a foot wide scarf, and now we’re into 10 meters and now we’re on the inside.

Yeah. And the outside. Why did you not do an NDT? It seems like money well spent Yeah. To do, especially if you have a, a quantity of them. And I think the quantity is a key now because in the US there’s 75,000 turbines worldwide, several hundred thousand turbines. The number of turbines is there. The number of problems is there.

It makes more financial sense today than ever because drone [00:11:00]information has come down on cost. And the internal rovers though expensive has also come down on cost. NDT has also come down where it’s now available to the masses. Yeah. But it has been such a mental barrier. That barrier has to go away. If we’re going going to keep blades in operation for 25, 30 years, I

Joel Saxum: mean, we’re seeing no

Allen Hall: way you can do it

Joel Saxum: otherwise.

We’re seeing serial defects. But the only way that you can inspect and or control them is with NDT now.

Allen Hall: Sure.

Joel Saxum: And if we would’ve been on this years ago, we wouldn’t have so many, what is our term? Blade liberations liberating

Chris Cieslak: blades.

Joel Saxum: Right, right.

Allen Hall: What about blade route? Can the robot get around the blade route and see for the bushings and the insert issues?

Chris Cieslak: Yeah, so the robot can, we can walk circumferentially around that blade route and we can look for issues which are affecting thousands of blades. Especially in North America. Yeah.

Allen Hall: Oh yeah.

Chris Cieslak: So that is an area that is. You know, we are lucky that we’ve got, um, a warehouse full of blade samples or route down to tip, and we were able to sort of calibrate, verify, prove everything in our facility to [00:12:00] then take out to the field because that is just, you know, NDT of bushings is great, whether it’s ultrasonic or whether we’re using like CMS, uh, type systems as well.

But we can really just say, okay, this is the area where the problem is. This needs to be resolved. And then, you know, we go to some of the companies that can resolve those issues with it. And this is really about played by being part of a group of technologies working together to give overall solutions

Allen Hall: because the robot’s not that big.

It could be taken up tower relatively easily, put on the root of the blade, told to walk around it. You gotta scan now, you know. It’s a lot easier than trying to put a technician on ropes out there for sure.

Chris Cieslak: Yeah.

Allen Hall: And the speed up it.

Joel Saxum: So let’s talk about execution then for a second. When that goes to the field from you, someone says, Chris needs some help, what does it look like?

How does it work?

Chris Cieslak: Once we get a call out, um, we’ll do a site assessment. We’ve got all our rams, everything in place. You know, we’ve been on turbines. We know the process of getting out there. We’re all GWO qualified and go to site and do their work. Um, for us, we can [00:13:00] turn up on site, unload the van, the robot is on a blade in less than an hour.

Ready to inspect? Yep. Typically half an hour. You know, if we’ve been on that same turbine a number of times, it’s somewhere just like clockwork. You know, muscle memory comes in, you’ve got all those processes down, um, and then it’s just scanning. Our robot operator just presses a button and we just watch it perform scans.

And as I said, you know, we are not necessarily the NDT experts. We obviously are very mindful of NDT and know what scans look like. But if there’s any issues, we have a styling, we dial in remote to our supplement expert, they can actually remotely take control, change the settings, parameters.

Allen Hall: Wow.

Chris Cieslak: And so they’re virtually present and that’s one of the beauties, you know, you don’t need to have people on site.

You can have our general, um, robot techs to do the work, but you still have that comfort of knowing that the data is being overlooked if need be by those experts.

Joel Saxum: The next level, um, commercial evolution would be being able to lease the kit to someone and or have ISPs do it for [00:14:00] you guys kinda globally, or what is the thought

Chris Cieslak: there?

Absolutely. So. Yeah, so we to, to really roll this out, we just wanna have people operate in the robots as if it’s like a drone. So drone inspection companies are a classic company that we see perfectly aligned with. You’ve got the sky specs of this world, you know, you’ve got drone operator, they do a scan, they can find something, put the robot up there and get that next level of information always straight away and feed that into their systems to give that insight into that customer.

Um, you know, be it an OEM who’s got a small service team, they can all be trained up. You’ve got general turbine technicians. They’ve all got G We working at height. That’s all you need to operate the bay by road, but you don’t need to have the RAA level qualified people, which are in short supply anyway.

Let them do the jobs that we are not gonna solve. They can do the big repairs we are taking away, you know, another problem for them, but giving them insights that make their job easier and more successful by removing any of those surprises when they’re gonna do that work.

Allen Hall: So what’s the plans for 2026 then?

Chris Cieslak: 2026 for us is to pick up where 2025 should have ended. [00:15:00] So we were, we were meant to be in the States. Yeah. On some projects that got postponed until 26. So it’s really, for us North America is, um, what we’re really, as you said, there’s seven, 5,000 turbines there, but there’s also a lot of, um, turbines with known issues that we can help determine which blades are affected.

And that involves blades on the ground, that involves blades, uh, that are flying. So. For us, we wanna get out to the states as soon as possible, so we’re working with some of the OEMs and, and essentially some of the asset owners.

Allen Hall: Chris, it’s so great to meet you in person and talk about the latest that’s happening.

Thank you. With Blade Bug, if people need to get ahold of you or Blade Bug, how do they do that?

Chris Cieslak: I, I would say LinkedIn is probably the best place to find myself and also Blade Bug and contact us, um, through that.

Allen Hall: Alright, great. Thanks Chris for joining us and we will see you at the next. So hopefully in America, come to America sometime.

We’d love to see you there.

Chris Cieslak: Thank you very [00:16:00] much.

BladeBUG Tackles Serial Blade Defects with Robotics

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Understanding the U.S. Constitution

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Hillsdale College is a rightwing Christian extremist organization that ostensibly honors the United States Constitution.

Here’s their quiz, which should be called the “Constitutional Trivia Quiz.”, whose purpose is obviously to convince Americans of their ignorance.

When I teach, I’m going for understanding of the topic, not the memorization of useless information.

Understanding the U.S. Constitution

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