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GE Vernova Q3 Results, Offshore Wind Struggles Worldwide
Allen, Rosemary, and Yolanda discuss the IEA’s 27% cut to offshore wind forecasts, GE’s wind financials, and Ming Yang’s revolutionary 50MW dual-rotor turbine. Register for the next SkySpecs Webinar!
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!
You are listening to the Uptime Wind Energy Podcast brought to you by build turbines.com. Learn, train, and be a part of the Clean Energy Revolution. Visit build turbines.com today. Now here’s your hosts, Allen Hall, Joel Saxon, Phil Totaro, and Rosemary Barnes.
Allen Hall: Welcome to the Uptime Wintery Podcast. I’m your host, Allen Hall in the Queen city of Charlotte, North Carolina.
Rosemary’s in Australia on her way to Sydney and Yolanda Padrone is here on site at a wind farm in Texas and there has been a, a number of news articles this week. Joel’s over actually in Copenhagen enjoying, uh, the sites and sounds of that great city, the International Energy Agency slash its five year offshore wind growth forecast by.
Are you ready for this? 27% citing policy shifts, obviously in the United States and [00:01:00] project cancellations across Europe and Asia. The big one in Asia is the Japan’s Mitsubishi pulling out a couple of projects there when costs, um, more than doubled according to them. And Denmark is changing from, uh, negative bidding auctions in favor of contracts for different, so there has been a, a big pullback in offshore wind.
It’s not zero, you know, it’s not going to zero at any time. I think there’s just a lot of projects that appear to be reassessing the interest rate environments, the ability to get turbines, the cost of ships, everything. And rosemary in Australia, it does seem like there’s been a little bit of a pullback there too for offshore wind.
Uh,
Rosemary Barnes: yeah. I mean it’s, it’s hard ’cause we’re still like in such a, just a nascent part of the. Industry. It’s still really far from clear whether we need or are going to get any offshore wind at all. Victoria has some pretty solid commitments to it. The government [00:02:00] does so. That’s probably as close as, um, anything to being certain that we’ll get some offshore wind.
But, um, probably we’ve all learned, America has shown us that a political com commitment is not as, you know, a government commitment is not as locked in as what we probably would’ve thought it would mean, um, a few years ago. So, yeah, we’ll see. I think Australia is struggling like the rest of the world.
We’re struggling a bit just in general with getting projects to, um, FID and. You know, getting construction actually underway and offshore wind is just like, you know, the same problems but on steroids. So it’s no surprise that you’d be seeing more challenges there. There’s been a few projects that have, um, been canceled or paused, but you know, they weren’t at the point where there were definitely going ahead.
So it’s, you know, like there’s a huge pipeline that makes almost no sense for how many projects there are in planning. Obviously some of them are going to [00:03:00] not go ahead, probably most of them. Um, and yeah, so we’ll, we’ll probably see many more cancellations and I think we’ll see at least a few offshore wind farms and probably those early examples are gonna dictate a bit how easy it is for other people to follow, or how much anyone even wants to follow.
Allen Hall: Well, is it gonna become a case where. Certain countries are, uh, focused on certain energy sources like France and Nuclear, and the UK will be offshore wind, onshore wind, and solar. Germany sort of a mix of everything, coal for a long time and they’ve gone away from nuclear there. But it does seem like every country has its own specialty and is that where we’re headed, that we’re just gonna see the best solution for each particular part of the world?
Rosemary Barnes: It’s really hard to get very decarbonized grids if you specialize too much. Like there. There really isn’t a technology that can just do everything, um, on its own. So, you [00:04:00] know, solar power is very, very cheap, but the sun sets at night. So obviously you’re gonna, at the very least, need some batteries to get you through the evenings if you’re relying mostly on solar power and then wind energy, obviously it’s not windy every day, even in really windy places like Denmark in the uk it’s still, you know, there are wind lulls, so you’re not gonna be able to rely solely on that nuclear power, just kind of chugs along at a fairly, um, you know, constant output.
If you turn it up and down too much, then you’re gonna end up, you need to like overbuild a lot. If you try and size your, your new, your electricity system just based on nuclear meeting, peak load, that’s a whole lot of reactor that’s gonna be not doing much most of the time, aside from the technical complications with being able to turn up and down.
And then even, you know, some of the traditional fossil fuels don’t do a very good job at responding flexibly. Coal power has, you know, similar issues to nuclear and it’s probably even harder to turn up and down. Um, [00:05:00] and then I guess gas is gas Peakers could, you could probably do everything with gas peakers if you want it.
They can turn on and off very quickly. But, uh, the. Gas picker plants are not very efficient. So there’s very high fuel costs and not to mention the, um, climate impact of just burning gas all the time and all of the, um, upstream emissions that come from a gas system. So I don’t think it’s possible for anyone to specialize too much, but of course, every country has technologies that they’re familiar with and comfortable with.
It’s never gonna be the sensible engineering decision to just go all in on one technology.
Allen Hall: Will batteries be the connector? For most of these technologies, and I bring this up because there’s been a lot of more recent discussions about data centers and Yolanda hop in here too because, uh, you work for an operator that was involved with batteries.
But the more, and I’ve been following this relatively closely the last month in doing more and more research in it, but like the, the [00:06:00] Colossus two that Elon’s building in Tennessee, there’s a big part of that distribution. From generation to delivery to the AI data center is a massive amount of batteries because of the up down nature of that load that they need a buffer.
Well, we see more batteries be deployed because of the AI data centers. And is that, can that be leveraged the other way to help balance out a grid that does have a lot of solar? It does have a lot of wind because the data centers are gonna be generically spread around. Countries.
Yolanda Padron: Yeah. Uh, yeah, I think it’s, it, the data centers should definitely, I, I mean, it does look like everything’s trending, right?
To have them, um, include batteries as part of their, of their scope to be able to balance everything out. I know we’re seeing, especially in the us like a lot of the, um, the behind the meter [00:07:00] projects coming online and taking advantage of the, the wind and solar, but. For those rolls where we might not get the perfect generation that they need to be able to exist.
Right. Like the batteries will definitely, uh, be that bridge, uh, to fill the gap there.
Allen Hall: Yeah. And even in the Colossus case where they have gas turbine generation and they’ve taken over an old power plant that was across the river in um, Mississippi, they’re still putting massive batteries in rosemary.
Because the data centers are, I think the consumption has always been that data centers are gonna be this kind of constant power input and that the computers are all gonna be working at maximum all the time. But what they’re finding is that it is not because they’re being trained at their moving up and down from like 10% of capacity to a hundred percent.
So the grid’s not made for that?
Rosemary Barnes: No. I mean, uh, the, the grid’s [00:08:00] not, I mean, when did the, was the grid. Designed or was it even designed, you know, like a hundred years ago and we kind of just, um, patched, patched it together as we needed to. It’s not like there, there wasn’t some yeah, like type of load that the grid was designed for.
People have always just made do with what they had available and then adapted to the characteristics of that. I mean, I don’t know, do you have off peak water heaters in the US because in Australia we have like, you can get a separate, a separate. Signal coming to your house that will turn on and off, uh, your electric water heater in off peak times.
And in the past, like traditionally, that was always overnight and it was specifically done. Like we specifically put all of this infrastructure in place to do that because there needed to be something to use the electricity that coal power plants were generating overnight. So, you know, like it was, um, you, you take what you can get as far as electricity generation and then you, you use it in the most effective way that you can come up with.
Allen Hall: Let me understand that for a minute because I’ve never heard of [00:09:00] this before, and I, I, we, you and I have been talking about energy for 20 odd years at this point, but, so they would turn on your water heater in your home to act as a load for the coal fired electricity plant.
Rosemary Barnes: You have a separate circuit that has off pa loads on it, which is usually just a hot water heater.
And then you can get, um, at. Different tariff from your electricity provider. There’s the regular and then the off peak timing. ’cause this is before anyone had any smart meters and you actually like, you know, the dumb old meters, they knew how many kilowatt hours you had used in a quarter, you know, but they didn’t know hourly.
Um, so this was a way that you could give a cheaper rate for people to heat their hot water. Overnight when there wasn’t enough natural load to be able to use up all of what the coal power plants needed to keep on putting out. ’cause you can only turn them down to a certain base load. Makes sense to use resources efficiently, like of course it does.
Um, that’s why it’s, I just find it really [00:10:00] weird how, um, like really. Emotionally upset, but people get really, get their feelings hurt by the idea that the energy transition might mean that you would change your behavior based on, um, you know, like what the, uh, electricity generation happened to be like that day, but it’s always been done.
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GE Re Nova’s Wind Business’ Engineering. Somewhat of a comeback and a third quarter. Results came out today as we record and revealed, uh, EBITDA losses narrowing to just $61 million from 317 million a year ago. An improvement of over 1000 basis points, which means 10%. Uh, the turnaround strategy, from what I could tell, is starting to work.
The wind services for onshore wind is up by 50. 3%, uh, in offsetting some equipment, uh, payments. And then the CEO Scott Straza emphasized that the company’s focused on profitability over volume with better pricing and reduced offshore contract losses, driving the improvement. They’re still waiting for a payment, it sounds like, from one of the cancellations.
Of around $500 million. So that’s still hanging out there. I wonder who that is. Uh, [00:12:00] but, uh, the, the booked orders this quarter are slightly down for wind. In general, GE thinks, Renova thinks they’re gonna close out Dogger bank and vineyard wind in 2026, which is sort of what we’ve been talking about on the podcast.
It’d be hard to finish both of those this year. So this is sort of a positive sign in, in, in terms of the larger GE with all the electrification and grid, uh, and gas turbines that GE is selling. There’s a huge upside there. Although the market was not particularly happy with this announcement today, I think it dropped a couple of percentage points.
Although since becoming a separate company, they’re up like 300%. It’s crazy. So if you invested on that opening day, which was like what, back in April a couple of months ago, you have done extremely well and I, is there hope for the onshore wind market for GE in the us or is it mostly [00:13:00] going to be. Yolanda, is it gonna be overseas?
Is that where GE needs to go right now because of the slowdown in us,
Yolanda Padron: I think until things for when stabilize a bit more in the US it’ll have to be outside of the us Right. Like their, like you mentioned, their current model relies a lot on having, I mean working a lot more on repairs and everything than actually building new sites.
Um, and I think. We’ve talked about wind in the US maybe ramping down a little bit while everything stabilizes a bit more for that. Yeah, I think it, it makes sense for GE to, to look elsewhere for now.
Allen Hall: Is there a stabilization of the marketplace coming? I know a lot of the talking heads and the, the banking units and if you listen to podcasts, financial podcasts, they’re saying, well this is really good for wind and solar to go through this little period of, uh, becoming more efficient.
And I [00:14:00] think. Uh, the prices of wind turbines have dropped pretty well and solar have dropped a lot. The, the industry is very efficient at the moment. It really has more to do with financing, from what I can tell.
Rosemary Barnes: Wind energy, is it cheaper in the US than it was like two years ago, three years ago, five years ago?
Allen Hall: Yeah. So because you’re generally putting up fewer turbines ’cause the turbines get larger and that they’re more efficient. Right. Um, the. They’re designed more specifically for the winds in a particular area, like low wind and middle wind conditions. I think overall they have been more efficient and as you know, having worked at LM every penny counts.
Rosemary Barnes: Maybe I have the opposite beauty to you. I’m having a, a bit of a, I don’t know, slump in my optimism. I’m, in general, I’m a naturally pessimistic person and um, it’s one of the reasons. That I work in, the energy transition is because I actually feel much more optimistic about progress the more that I, I [00:15:00] know about it.
But at the moment, wind energy, I, I, I’m pretty sure it is not accurate to say wind energy is cheaper, getting cheaper in Australia. It’s costing more. To put turbines in in Australia than it used to. And then I’m also super cynical about, you know, the efficiency savings and cost savings, especially of big companies like ge because what I see is them, they, uh, you know, have a bunch of quality problems from, you know, the work that they were doing in the late 20 teens, um, maybe, yeah, early 2020s.
Bunch of quality problems. So then that costs money. ’cause you know, you’ve got warranties to pay out on and um, things to fix and sales that get canceled. And it seems to me like their solution to that. Their money saving is we’ll just fire most if not all of the engineers. So that’s really good way to save money this year, but it’s not very good way to make sure that you don’t have more warranty problems next year and the year after.
Not a good way to make sure that you’re [00:16:00] able to. Uh, you know, come up with solutions to problems in a timely manner. It’s kind of like, is this the beginning of the end? Because once they’re gone, how do you get them back? I mean, maybe in one or two years time, it’s gonna be an amazing time to be a blade engineer because, um, you know, everyone will be, will be desperate, desperate for, for you.
But it’s, um, uh, I, I, I don’t, I, I can’t get on board with the, you know, the efficiency gains that like, that we’re seeing at the OEMs at the moment.
Allen Hall: I know you’re just a wee kindergartner when the year 2000 was around, but if you think about 20 years ago, there was, at least in the United States, no one was thinking about wind and really few people were thinking about solar and maybe unless you lived in California.
But today, solar is everywhere. You can drive down the street and see solar in most places, and wind is in a lot of parts of the United States and the world at the same time. So. The amount of growth in the industry in the last 20 years has been truly [00:17:00] remarkable. And to say it’s gonna go through some cycle, I think is normal.
Every industry goes through booms and busts.
Rosemary Barnes: I think in the past it was more of a manufacturer by manufacturer basis, so you know, vest would have some quality problems and then they would, you know, get it back under control and a few years later they’re fine Again. LM had quality problems and then got it back under control.
And you, like I said, it kind of cycled through. But now, like who is not having blade problems at the moment? Nobody. I honestly, I don’t. I, I don’t think there’s anybody not having, having problems at the moment. Um, and yet people are laying off more engineers than they’re hiring, that’s for sure. By, like, by a significant margin.
What I think that the industry needed was to do a better job of selling the same platform over and over and over again, so that it got really well known, and then moving up to the next one. After sufficient testing of new [00:18:00] features, then, you know, move up to a new platform and sell a lot of that. Use less engineering by having less design.
Yeah, less designs that you are trying to support at the same time, less new designs that you’re trying to develop. That’s the way to reduce the cost you’re spending on engineering, not to continue to have, you know, millions of different designs and features and constant, constant growth for the sake of growth.
Um, maybe that’s a segue into the next topic. Um, but you know, like you can’t do that without a whole lot of engineering. So it is like, you know, you, you choose, either you have heaps of engineering and heaps of innovation, or you kind of just, um, settle down and do one thing really well, and then you can have less engineering
Allen Hall: as wind energy professionals.
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Don’t miss out. Visit PS wind.com today while the contrast couldn’t be starker while Western manufacturers struggle, as Rosemary has pointed out. China’s been Yang. Spart Energy Group is preparing the world’s most powerful wind turbine, a two-headed 50 megawatt giant that. Dwarfs anything that’s currently operating, uh, production supposedly begins next year at a facility in Guangdong Province.
Uh, Ming Yang plans off of this tournament at below $1,400 per kilowatt. So remember we’re talking about Rosemary and the price per kilowatt is going down where the Ming Yang is truly really trying to drive it down. If, if you look at the. Numbers in comparison to European manufacturers, that’s a pretty low number.
Even in comparison to existing Chinese manufacturers. That number is still like a 20% [00:20:00] discount.
Rosemary Barnes: Is that the price that you would get it for a project in Europe? So with, um, you know, IAC certification ’cause I know that they work to a different certification standard in, in China and that it costs a bit more to, um, have it, you know, designed to pass the.
The is a stunt that everybody else uses.
Allen Hall: Exactly. So the question is, and going back to the engineering thing, it’s a two-headed turbine. So it’s got that V platform, it’s an offshore floating turbine of course. And it’s got that V connection and it’s got two heads, two uh, the cells, and two massive rotors on it.
That has to have a lot of engineering behind it. I hope it does. They haven’t built one.
Rosemary Barnes: Yeah, it’s, uh, so they’ve done, they’ve done some parts of it before. I mean, they’ll make like a really, a really huge offshore turbine, but it’s not like there are. Hundreds or thousands of 25 megawatt turbines out there in the ocean.
There are not hundreds or thousands [00:21:00] of floating wind turbines of any kind in the ocean, and there are not hundreds or thousands of, um, multi rotors of that, you know, v design that they’ve done. So it’s three, it’s three really big hard things or combined in one. Um, and yeah, it’s a big. A big step before they probably, they probably don’t know the, all of the, the risks and failure modes of any of those three individual things.
And now they’re gonna combine them and get new, new problems from combining things together. So. It will be for sure. A lot will be learn from this. Um, I, it seems like too big of a step to be like, yeah, you’re gonna be able to order one of these and have a gigawatt wind farm with these put in and, you know, 2028.
That’s not within this realm of reality. But as a learning exercise, I mean, that’s what China does really, really well. They don’t plan to the extent that, um, [00:22:00] Western companies do. They don’t. Get every I dotted and t crossed before they will actually execute on a project. And you can definitely learn way more that way, but with much bigger risks
Allen Hall: in terms of certification and standards.
For a turbine that is non-standard, how many years would it take to create just the specifications and the test process to validate it? I, I think we’re talking about a minimum of. Five years of all the committee meetings, you’d have to have to even get close to having something where like A DNV could put a stamp on it, right?
Rosemary Barnes: Yeah. I mean, there’s a whole bunch of potential failure modes that don’t exist in the turbines that we have today and the standards that we have today. I mean, the standards haven’t even kept up with just regular, like garden variety, one turbine on a stick, three blades, you know, all of that. There’s heaps of, heaps of common failure types that aren’t really covered [00:23:00] by the standard, so.
Um, yeah. I mean, when you get up to, to two turbines and I think that they counter rotate is, is that right? That they’re going opposite direction? I think you need that so that you don’t get funky tower dynamics happening. Um, however, uh, there are still going to be weird things happening with the aerodynamics.
Like di dynamic flow stuff is gonna cause weird things and that causes fatigue is the, you know, the main problem that you get from. Just, you know, just small. It might be, yeah, even just small loads that you didn’t expect in places that you didn’t expect them. Um, and fatigue damage can happen very quickly if it’s a, you know, if it’s a really big, big load.
But if it’s a, just a small but larger than expected load somewhere, it can take two years, five years, 10 years. Um, but then you get fleet wide failure. Um, and so it’s, it isn’t something that it’s very easy to, uh, test for at a scale. You know, with a scale model. So, [00:24:00] you know, in that sense it probably is the right thing to do to build a full sized one as soon as possible and, and learn those things.
You know, it makes me feel uncomfortable because wind turbines are things that people have to climb up in there to install them. People have to climb up in there to maintain them like a lot in the early days, especially with a new system. And so the fact that it could, you know. Fall apart. Risks are reduced if you make sure no one’s climbing it when winds are high.
’cause that’s usually when you’ll see failure. But it’s, it’s still higher than I would feel comfortable with. I wouldn’t like to be climbing inside, um, this turbine ever. Um, but yeah, it, it is. I can’t deny that that is probably the fastest way to, you know, progress technology.
Allen Hall: Alright, Yolanda, if, uh, Rosie’s offshore wind company decides to buy these 50 megawatt wind turbines as an asset manager and thinking about how, [00:25:00] how you would operate these turbines, what would be your top complaints right now?
Or top worries?
Yolanda Padron: Rosie mentioned earlier, right, that it would be in a perfect world. All of this innovation would be driven by engineering. Right? And being able to test these things over and over and over again, and being able to see exactly what problems we’re facing and how we can solve them for the most part.
Right. And just kind of all going up together in getting these, you wouldn’t really know. And we go back to that risk issue, right? You wouldn’t really know. What you’re buying at this point? Me personally, of course it was. If it was Rosie, I’d trust her with my life. So yeah, if Rosie’s doing it, yeah. But anybody else, you know, we won’t, we don’t know what they’re testing.
I mean, you, no one wants to be the Guinea pig,
Allen Hall: right? Well, someone will have to be, if they plan on selling it, someone will have to be the Guinea [00:26:00] pig. But it’s probably an operator in China, or maybe Mi Yang itself will have to deploy them. But. At some point, just listening to the, to the news in Europe, there’s a lot of push to bring in Chinese turbines that don’t have a lot of.
History or verifiable history, doesn’t it just raise the asset risk? I would say, whoa, whoa, whoa. Slow down everybody. The finance group, slow down.
Rosemary Barnes: You don’t see a lot of them in, um, Europe or you know, outside of the, um, outside of China yet. And. I mean, I wouldn’t consider it de-risk just because you’d seen a demo turbine turbine in China.
I wouldn’t consider it de-risk because you saw a whole wind farm of these in China, because they do do separate designs for separate, um, geographies. Uh, you know, they, like I said, with the certification, they, they change the design to be able to. To pass that. And, you know, even if you are making it safer, if you’re, you know, adding material, it doesn’t, it doesn’t always mean that it’s becoming more reliable.
Like you have to, you know, the track record [00:27:00] needs to be for the turbine that you’re actually buying, not something that they’ve assured you is very similar.
Allen Hall: That wraps up another episode of the Uptime Wind Energy podcast. Thanks for joining us as we explore the latest in wind energy technology and industry insights.
If today’s discussion sparked any questions or ideas. We’d love to hear from you. Reach out to us on LinkedIn and don’t forget to subscribe. So if you never miss an episode and if you found value in today’s conversation, please leave us a review. It really helps other wind energy professionals discover the show and we’ll catch you here.
Next week on the Uptime Window G Podcast.
https://weatherguardwind.com/ge-vernova-offshore-wind/
Renewable Energy
Malloy Wind and NSK on Main Bearing Failures
Weather Guard Lightning Tech

Malloy Wind and NSK on Main Bearing Failures
Cory Mittleider of Malloy Wind and Loren Walton of NSK on main bearing failures, why the industry is pulling DLC coatings, and the material changes replacing them.
Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTube, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!
Allen Hall: Cory and Loren, welcome back to the podcast.
Cory Mittleider: Thanks for having us.
Allen Hall: So we’ve got two bearing experts in one location, and this is the point where we start asking all of our bearing questions. Cory, you’re with Malloy Wind, and we’ve had you on the podcast two or three different times. Loren’s with NSK — we’ve had Loren on at least once before.
Loren Walton: Once, yes.
Allen Hall: Yeah, and that was good.
Loren Walton: I appreciate that. It was fun.
Allen Hall: There are a lot of bearing issues happening in the States at the moment, but also globally. Whatever happens in the States, you can pretty much find in Australia, Canada, Singapore, Mexico, South America, Brazil — everywhere. We’re hearing a lot about main bearings, and there’s a variety of things that I think you two know from being on the inside that we on the outside haven’t heard yet. I want to get some of those stories out and understand what’s going on, because operators are trying to keep their assets running, and bearings are a big issue. Let’s talk main bearings. What are you seeing in the field right now? What kinds of problems are happening?
Cory Mittleider: It seems like operators are coming to us and asking us to supply bearings that no longer have DLC. That’s a bit of a phenomenon lately. For a little over a decade we spent our time supplying bearings with DLC on the rollers to address problems found fifteen years ago.
Allen Hall: DLC is diamond-like coating.
Cory Mittleider: Correct.
Allen Hall: Which is a really hard specialty coating applied to the bearing surfaces to provide hardness and durability — or it’s supposed to provide durability.
Cory Mittleider: That’s a good point. It’s a coating that’s one to two microns thick — one to two thousandths of a millimeter — and a very hard material. The big feature was that it’s a dissimilar material to the steel. So when we break through the mixed and boundary lubrication regimes and those asperities touch each other, that dissimilar material prevents the welding and tearing that leads to the peeling damage we saw fifteen years ago. That peeling damage eventually turned into spalling, cracking, and other failures. So it made a lot of sense at the time to turn to something like this to mitigate the peeling.
Allen Hall: So the peeling damage was one of those issues where you basically had some sliding happening. In my electrical world, and from looking at these on the ground, you see things moving relative to one another instead of rolling relative to one another.
Loren Walton: It’s more of a welding and shearing of the contacts. I used a finger analogy last time: think of your asperities as fingers — one set is the roller, one set is the outer raceway. They weld under high load and high pressure, then they shear, leaving behind debris. That’s what creates the beginning of the peeling damage, and then it continues to create more debris, and the bearing starts to basically eat itself alive.
Allen Hall: The start of that process, though — is that a lack of lubrication, or a finish or hardness issue on the bearing?
Loren Walton: I love that question, because this is the crux of the whole thing, and I think it’s the part that gets missed. People immediately want to throw the whole thing out and start over with something different. Fundamentally, when we fixed the surface issue by adding the coating, the problems pretty much went away. We went from one-to-five years of life to ten-plus years, depending on the application — without changing the construction, the bearing type, or the contact angle. Just by adding the coating, we increased life significantly. The root of what you’re asking is that the bearing would operate better if it had the proper amount of separation. It’s not a fatigue issue and it’s not a loading issue. At its heart, the bearing isn’t able to create that separation. There isn’t enough speed, and there isn’t enough of a gap created by the lubricant.
Allen Hall: So ideally you have this almost molecular-scale film of lubricant between the two surfaces. If it isn’t designed properly, or you have an issue, that lubricant gets squeezed out of the space, and at that point you have trouble. That’s some of what I’m hearing on main bearings — especially when turbines have been curtailed and aren’t turning. Is that partly just the fact that there’s so much load?
Cory Mittleider: I think that’s a fundamental difficulty of the main shaft bearing. You’ve got extremely variable loads, from full load to idle, and a wide range of operating conditions — from northern North Dakota in the winter to Texas in the heat this week. High load, heavy load, incredibly slow speed, and even slower if it’s idling. It’s hard to reliably build that film. It’s not necessarily that there isn’t enough lubrication; it’s that the film isn’t building properly where it needs to be to separate the metal and the rolling elements.
Allen Hall: So the diamond-like coating was meant to solve that welding problem — you put the coated bearing in, and it worked okay until more recently, when all of a sudden we started having other issues. To me those aren’t related to the coating itself, but to other things happening up in the nacelle.
Loren Walton: If we recall some of your previous episodes, you were on the forefront of understanding and talking about DLC starting to become an accelerant to failure. I know you talked about it with Cory. Those episodes have aged very well. A lot of people now are recognizing what we were saying years ago and changing their strategy toward removing DLC — whether on bearings for newer turbines, typically two megawatts and greater, or in some cases going backwards and removing DLC as they do additional replacements, and looking for another solution, because there’s potential for additional issues you weren’t expecting by adding the coating.
Allen Hall: The coating is non-conductive, which is part of the issue, because you wouldn’t think bearings are conducting electricity. But as turbines got some of these uptower and downtower converters and inverters connected to the generator, we started seeing current levels — according to Motor Doc, where people like Howard Penrose have gone out and measured currents in the nacelles — of well over a hundred amps running through ground straps and the like, into bearings. That’s a lot of current. If you’re shoving that into a bearing that has DLC on it, you’re going to break it down and create these really hard steel bits stuck inside the bearing, which wear it like pouring sand inside a bearing. That’s what eventually happens, and it has nothing to do with the bearing. It has more to do with the electrical and control systems we stuck up top and didn’t pay much attention to, but probably should have. We created an electrical situation, and now all the upkeep comes to people like you to deal with. You haven’t seen a lot of work to eliminate it, although there are a couple of good attempts happening. The reality is: okay, we have to have a bearing, and I’ve got this current going around from the nacelle. How do I put those together in a way that removes the DLC?
Cory Mittleider: That’s what we’ve spent the last ten-plus years on. As a bearing supplier, we can’t change the whole system. We have to do the best we can to accommodate what’s happening in your system. We would absolutely encourage you, if you can identify and remove the electricity, please do that.
Allen Hall: They should. And there are a lot of people who do.
Cory Mittleider: There’s a pursuit of that, absolutely. But the turbine still needs to run.
Loren Walton: We work very closely with an owner-operator that did a lot of that work. To your point from before, it does sound like, from what they’ve investigated, the current has been there for a while. It’s been there in different models and different turbines. Maybe the way it presented, or its impact, wasn’t to the same extent as what we’re seeing now. That’s where I’d say there’s more to it than just the current. I think I said last time it’s not just a smoking gun. The bearing is sitting in front of a firing squad. You put it all together and now we’re in a tough position. But to Cory’s point, we get brought the application, we get brought the environment, and we get told, “Here, make it work.”
Allen Hall: And you don’t actually see everything that’s happened. You get all the mechanical loads, but they don’t tell you, “Hey, we’re running a hundred amps through this nacelle.”
Loren Walton: No, I don’t remember hearing that.
Cory Mittleider: No, that’s not usually disclosed.
Allen Hall: No one’s ever said that. So that’s a real troubling thing happening in the industry — we’re assigning blame to mechanical components when really it’s an electrical mistake. When you dig into it, what you find is that currents have been running up top for years, but what’s changed now is that with more focus on emissions from inverters, they’ve pushed things into higher frequencies. Higher frequency bands are harder to ground out and get rid of. When things were in the kilohertz range, we could partly ground them and they’d go away. Now we’re working at ten kilohertz and up, and that energy distributes into a lot of places, including the bearings, where it wasn’t before. That’s really hard to deal with. Some electrical designer sitting in a remote location, probably in Germany, designs the circuit, and now you bearing gurus have to go fix it.
Cory Mittleider: And that system’s probably well optimized for that particular package.
Allen Hall: For that particular package, right. It meets all the requirements and does everything they wanted — except for the effect on the bearings.
Loren Walton: You solve one problem and move it to another. That’s ultimately how it works.
Allen Hall: If you’re an electrical engineer, you’d never have thought you were destroying the bearings. The industry has moved quite quickly, though. Everybody started noticing this problem with DLC. They went out to check and figure out what the problem was, and, more importantly, to find a solution. Those solutions are unique, because the reason DLC went on in the first place was to extend lifetime. So if you’re taking the DLC out of the equation, can you still get to those lifetime numbers without it?
Loren Walton: Yeah, and that’s where our message has been that adjusting the material will get you the difference you’re looking for. I want to be very clear: I’m not saying DLC as a solution is bad. When it was applied in the right space — turbines with a lighter duty — it worked great. But once you add in additional factors, it becomes an accelerant to failure at certain points. So it definitely still has its place. But once you move away from DLC, you’re going to be right back where you started — regardless of construction — with the life that was always aided by DLC. Once you’ve removed it, you have to know for sure you’re not going right back to the peeling layers and the spalling you were seeing. From what we’ve investigated, the material changes are where you get that. Having a harder surface combats it, and having a better way to combat any additional debris introduced into the system helps.
Allen Hall: And reducing the possibility of generating that debris.
Loren Walton: Correct.
Allen Hall: So what does that mean in terms of bearing design — different alloys, different heat treats, different coatings?
Loren Walton: The first two, not the third. From the recipe of the steel, adjusting some of the alloying elements, there’s a lot you can do. A lot of people think of engineering mostly through the mechanics of it, but one part of mechanical engineering that doesn’t get talked about is material science. That’s the part we dive into extremely deeply, and it gives you the biggest bang for your buck when you’re moving away from a coating as your — I don’t want to call it a crutch, but as the thing helping you get by — toward changing the bearing from the inside so it lasts better once the coating is gone.
Cory Mittleider: I like describing it as being baked into the cake. It’s not a nice thing added afterward like a coating that’s one to two microns thick. It is the bearing.
Allen Hall: It’s hard to think about steel and a lot of the metals used in the bearing industry as unique chemistries, but they are. There are a lot of varieties of steel, just like there are a lot of varieties of copper or aluminum.
Loren Walton: Yes.
Allen Hall: You’d think steel is just steel — we make cars out of it, airplanes, whatever.
Loren Walton: I was talking to someone who’s more into gears, and even when I spoke of a carbon-nitride version of a bearing versus a carbon-nitride version of a gear, it’s not exactly the same. For all intents and purposes it’s easier for everyone to consider it as steel — one word, means the same thing. But once you get into how much chromium is in it, how much molybdenum, how much manganese —
Allen Hall: It comes down to that, and it can be very small percentages of the total.
Loren Walton: It can make a huge difference. And then you get into the heat treat — your time, your soaking, what you do for quenching. It all matters, and everyone does it differently, so you get different results.
Allen Hall: That’s the kicker. You see a lot of discussions where it’s just, “Oh, it’s been heat treated.” As an electrical engineer I used to see it that way too. But there’s heat treatment and there’s heat treatment. It depends on what you’re doing and what the result needs to be, because you’re changing the whole crystalline structure of the steel. The way you do it and the way you quench it all matters. It’s not one size fits all.
Loren Walton: That’s the part that gets glossed over so quickly, because everyone’s eyes go to what they can see. You change an angle here or there, or the bearing type, and you can see that. It’s different when you don’t have X-ray vision to tell you where all the alloying elements are and in what percentages, and then whether you carburized it, through-hardened it, or carbonitrided it. There’s so much to it that I can see people’s heads start to spin. That’s where we say there are a lot of experts out here — you two are among them, and there are others. Engage in conversations. Ask questions.
Allen Hall: That’s a great call to action — “Cory, help me understand what’s going on.” There’s a variety of bearings out there. Loren’s with NSK, a great bearing company with tremendous history. Those are a couple you can trust. But operators can feel inundated by the guy down the street trying to sell them a bearing, and you don’t know if that’s the right solution for your two-million-dollar wind turbine.
Cory Mittleider: These are critical infrastructure assets. Let’s make sure we understand what we’re doing and why. To Loren’s point, you can open three boxes and they all look the same, but what’s inside is what really matters.
Allen Hall: It’s a tremendously difficult business. With as many main bearings getting swapped out today, over the last couple of years there have been a lot of decisions made on the fly — some correct, some really wrong.
Loren Walton: I’d hesitate to say wrong, because I think people are doing the best they can. It’s not because they’re not trying.
Allen Hall: It’s because they don’t have the knowledge in front of them, or maybe they haven’t made the call to Malloy or NSK yet to get the ground truth.
Loren Walton: What you mentioned a second ago is pivotal. There’s been enough selling that we’ve kind of gotten away from the engineering. People hear “sales engineer” and they cut off at “sales.” If we can get back to the engineering, a lot more people will improve their assets. And it doesn’t have to be just listening to Cory and me — poll the audience. There are a lot of us out here. Everybody has a different background; we all know a little about this or a lot about that. Take the opportunity to learn. I’d liken it to your personal life: you wouldn’t buy a new vehicle or a stereo system without doing your own research. You wouldn’t just listen to the salesperson and buy the first thing you see. It’s the same here. If you’re making decisions without engaging at least the top three to five people in this space, you’re doing yourself a disservice.
Allen Hall: And that’s what happens a lot, because people get pushed. There’s a timeline, especially now with the repower situation — “I’ve got to put something on now.”
Cory Mittleider: Right. And new platforms — the next-generation three, four, five, six megawatt platforms, and offshore — are having their first failures. We need to learn from it. That’s where we’ve worked with operators to participate in the teardown and collect the sample. We get clues, we mark it up, and we do a lot of the investigation — metallurgy, metrology, raceway traces — to inform us on what the problem is on that specific platform.
Allen Hall: As we get to these bigger turbines, some data is coming back on O&M costs relative to a one or two megawatt machine, and it doesn’t scale linearly. It goes almost exponentially, because everything is more expensive. Replacing a bearing on a six megawatt machine is a much more expensive ordeal than on a two megawatt machine. What should we be paying attention to and monitoring more closely on these larger machines? The new shiny turbine is great, but that doesn’t mean you don’t have to monitor and maintain it.
Loren Walton: I’d start with verifying all your original fits and clearances. We’ve had cases with a four-point mount main shaft — two main bearings — where one side wasn’t installed properly from the beginning, so it didn’t actually float. It’s supposed to be a fixed side and a floating side; now you’ve got one side that’s not floating, and you get overload. So make sure you’re set from the start. A lot of machines now come already outfitted with instrumentation — vibration monitoring, oil monitoring, different ways to start trending from the beginning. Back when we got started, that wasn’t the case. You got your new turbine and in a lot of cases it had nothing on it — you were flying blind. Now that it’s there, use it.
Cory Mittleider: That’s a good point. Specifically to bearings, something earlier versions didn’t have, and newer ones mostly do, is auto-lubers.
Allen Hall: I see more of those lately.
Cory Mittleider: That’s great from a lubrication-delivery and reliability point of view, but it’s its own little machine. We’ve heard of cases where the auto-luber failed, or ran when it shouldn’t have, or for whatever reason had very large output. So you need regular assessment of the entire system, including uptower.
Allen Hall: You’ve got to monitor everything that’s uptower.
Cory Mittleider: It’s its own little machine. It requires its own maintenance. If you’re relying on it, you’ve got to check it.
Allen Hall: As we move into these larger machines and see more of them deployed, what are the useful things you should be doing in that first year to make sure your bearing is working optimally? Is it just checking vibration levels? Is it getting uptower and doing a quick sweep to confirm the grease isn’t oozing out where it shouldn’t be? Is it that simple?
Loren Walton: Having a regular maintenance interval definitely helps. Even getting grease sampling to understand your baseline levels after the first six months and the first year. In a lot of cases the turbines are under a couple-year warranty, so maybe you don’t have as much access. But as much as you can, getting a baseline is huge, because you’re going to want to compare later. You’ll want to say, “Okay, I took this grease sample — what does it mean? Does it normally run that high or not?” Same for vibration, getting the trending. For main bearings in general, more grease is better than less, because you can never quite get it all out when you’re regreasing. So a lot of that first year or two is about getting a good baseline so you know what you’re actually expecting, and what it means when you take a reading in year two or three.
Allen Hall: What does a grease sample look like in terms of the response you get back? I take a sample, send it to a lab, and it comes back with — what? Is it “good or bad,” or a bunch of chemical numbers about composition and dirt? I’ve never seen one.
Cory Mittleider: It’s a matrix. You can request different versions, but probably ten or fifteen different elements they give you numbers on, in parts per million. Iron and brass will be up there.
Allen Hall: So if you see something floating in the grease —
Cory Mittleider: Silicon, phosphorus, water.
Allen Hall: Water would not be great.
Cory Mittleider: No.
Allen Hall: So those reports come back, and I assume there’s more knowledge needed to interpret the results. What do you do?
Loren Walton: We have some guidelines we share with our partners and customers. If you see a certain amount of parts per million of copper, ferrous material, or the like, we can say, “That’s worth monitoring for a while,” or “You should probably purge it, try to get it out, and see if it stabilizes.” We get those questions and respond in kind. There’s definitely help available. If we work together, we typically have a lot more success. A lot of people right now feel like they’re trying to work in their own silos, and you don’t have to do that. You don’t have to be the subject-matter expert for lubricants, gears, bearings, and everything else. You can reach out to experts who can help, and hopefully that frees up your time to assess and work on other things.
Allen Hall: The turbines are so complex today. It used to be you could have one person on site who knew most of what was going wrong, because they’d made thousands of these things — there was a legacy. When you get to six megawatt machines, where you don’t have a lot of history, particularly in the United States, there’s really no one to ask. You’d better find somebody who knows what they’re talking about.
Cory Mittleider: And the operators are responsible for multiple systems — six or seven or eight systems they’re looking at. We can help with bearings; we’re niche and focused on that. If we can take that off your plate, now instead of six systems you’ve got five to worry about.
Allen Hall: That’s key. There are experts out there, and one thing the podcast is trying to do is give those experts a chance to talk so you know who to ask. Your phones should be ringing right about now, because it’s repower time, and it’s main-bearing repair and replace time, pitch-bearing repair and replace time. There’s a lot of bearing activity going on. I always say call Malloy Wind if you need somebody who really knows their stuff, the technology, and what’s going on internally. How do people get ahold of you two if they have questions? What’s the easiest way?
Loren Walton: I try to be at most of the industry events. We usually hold a booth. And my email, my phone number — I’m on LinkedIn, so reach out there. After our last discussion I had a few folks reach out, actually mostly from other countries. It was interesting; we heard about a few issues before they even hit the US. Some folks were having problems with the larger turbines, and we were able to get our teams in Brazil and Spain involved right away. Then once it started cropping up in the US, I could say, “Yeah, I already solved that.” We can put my email in the show notes.
Allen Hall: We’ll put it in the show notes for sure. And Cory, how do people get ahold of you?
Cory Mittleider: I’m pretty active at the events — ACP, and the Drivetrain Reliability Collaborative is another one we had a couple of months ago. Email, phone, and I’m pretty active on LinkedIn. I’ve had similar experiences to Loren, getting contacted from other countries across the globe. It’s fun to investigate problems and share results in the technical articles on our website, and have people send me a picture of an article I wrote and say, “Hey, let’s talk about this.”
Allen Hall: Your articles are great. Check out malloywind.com — just Google it and it’ll come right to the top. If you have bearing questions or something you’ve seen, that website is a great first place to get some answers. It’s very helpful. Well, Loren and Cory, I love having you on the podcast. We need to have you on more, because there’s a lot going on in the bearing world.
Loren Walton: There are things we didn’t even touch on today.
Allen Hall: You’re always welcome back.
Loren Walton: Awesome. Appreciate it.
Allen Hall: Thank you.
Renewable Energy
Wrong State
Minnesota is home to intelligent, well-educated people whose approval of Trump is lower than that of toenail fungus.
If Lindell wants to lead a state, he needs to choose one at least 800 miles away. Oklahoma?
He may also want to consider that Trump is easily the most detested person in this nation.
Renewable Energy
The Existence of God
I wouldn’t say that the burden of proof lies on religion. No one knows how the universe got here.
The Big Bang was an event in which there was no chaos, no “entropy,” as we say in thermodynamics. How did all this orderliness get there 13.87 billion years ago? No one knows. This is an issue in cosmology which is quite likely to outlast human civilization on this planet.
I’m an atheist for a few reasons, one of which is that saying that God created the universe doesn’t get us any closer to an understanding of the cosmos, if only because it raises the question: Who made God?
More to the point, there are hundreds of moral reasons to disbelieve in God. Each year, 9 million children will die unbaptized on this planet before their fifth birthdays. In the bible, we learn that God punishes them all with an eternity of torture in hell. To what sort of weirdo does this make sense?
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