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German Bird Study Finds 99% Avoid Turbines, SunZia Progress

Allen, Joel, Rosemary, and Yolanda discuss a German study finding 99.8% of birds avoid wind turbines, challenging long-standing collision risk models. They also cover Pattern Energy’s SunZia project nearing completion as the Western Hemisphere’s largest renewable project, lightning monitoring strategies for large-scale wind farms, and offshore flange alignment technology.

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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 host. Alan Hall, Joel Saxon, Phil Totaro, and Rosemary Barnes.

Allen Hall: Welcome to the Uptime Wind Energy Podcast. I’m your host Alan Hall in the queen city of Charlotte, North Carolina, where a cold front is just blown through, but we’re not nearly as cold as Joel was up in Wisconsin, Joel, you had a bunch of snow, which is really the first big storm of the season.

Joel Saxum: Yeah, the crazy thing here was the Wind Energy Podcast. So since that storm I, we, we got up in northern Wisconsin, 18 inches of snow, and then we drove down on last Saturday after US Thanksgiving through Iowa, there’s another 18 inches of snow in Des Moines. I talked to a more than one operator that had icing and snow issues at their wind farms all through the northern Midwest of these states.

So from [00:01:00] North Dakota. All the way down to Nebraska, Northern Missouri, over into Indiana. There was a ton of turbines that were iced up and or snowed in from that storm,

Allen Hall: and Rosemary was in warm Australia with other icing knowledge or de-icing knowledge while the US has been suffering.

Rosemary Barnes: But you know, on the first day of summer here, a couple of days ago, it was minus one here overnight.

So. Um, yeah, it’s, uh, unseasonable and then tomorrow it’ll be 35.

Allen Hall: The smartest one of us all has been Yolanda, down in Austin, Texas, where it doesn’t get cold.

Yolanda Padron: Never. It’s so nice. It’s raining today and that’s about it. Traffic’s going crazy.

Joel Saxum: Rain is welcome for us, isn’t it though, Yolanda?

Yolanda Padron: It’s sweet. It doesn’t happen very often, but when it does.

Very rainy for like 24 hours.

Allen Hall: We’ve been saving a story for a couple of weeks until Rosemary is back and it has to do with birds and a year long study over [00:02:00] in Germany. And as we know, one of the most persistent arguments against wind energy has been the risk to birds and permitting and operation shutdowns have been the norm, uh, based on models and predicted collision risks.

Well. A new study comes, has just come out that says, what if the models are all wrong? And the new German study suggests that they may be wrong. The Federal Association of Offshore Wind Energy, known by its German acronym, BWO Commission Research to examine. Actual collision risk at a coastal wind farm in Northern Germany.

The study was conducted by Biocon Consult, a German research and consulting firm, and funded by eight major offshore wind operators, including Sted, Vattenfall, RWE, and E, roa, and. Rosemary using some of the newer technology. They were able to track bird movements with radar [00:03:00] and AI and stereo vision cameras to, to watch birds move through and around, uh, some of these wind farms.

And it analyzed more than 4 million bird movements and over 18 months, and they searched for collision victims and what they found was pretty striking more than 99.8% of both day migrating and night migrating birds. Avoided the turbines entirely. The study found no correlation between migration intensity and collision rates.

And BD and BWO says The combination of radar and AI based cameras represents a methodological breakthrough. Uh, that can keep turbines moving even when birds are in transit. This is pretty shocking news, honestly, Rosemary, I, I haven’t seen a lot of long-term studies about bird movements where they really had a lot of technology involved to, besides binoculars, to, to look at bird movement.

The [00:04:00] 99.8% of the migrating birds are going around The turbines. No, the turbines are there. That’s. Really new information.

Rosemary Barnes: I think. I mean, if you never heard anything about wind turbines and birds, I don’t think you’d be shocked like that. Birds mostly fly around obstacles. That’s probably an intuitive, intuitive answer.

Because we’ve had it shoved down our throat for decades now. Wind turbines are huge bird killers. It’s kind of like, it’s been repeated so often that it kind of like sinks in and becomes instinctive, even though, yeah, I do think that, um, it’s. Not that, that shocking that an animal with eyes avoids a big obstacle when it’s flying.

Um, but it is really good that somebody has actually done more than just trying to look for bird deaths. You know, they’ve actually gone out, seen what can we find, and then reported that they found mostly nothing. We already knew the real risks for birds, like hundreds or thousands, even millions of times [00:05:00] more, um, deadly to birds are things like.

Cats. Cars, buildings, even power lines kill more birds than, um, wind turbines do. In fact, like when you look at, um, the studies that look at wind, um, bird deaths from wind turbines, most of those are from people driving, like workers driving to site and hitting a bird with their cars. Um, you know, that’s attributed to wind energy.

Not a surprise maybe for people that have been following very closely, but good to see the report. Nonetheless.

Joel Saxum: I think it’s a win for like the global wind industry, to be honest with you, because like you said, there’s, there’s no, um, like real studies of this with, that’s backed up by metric data with, like I said, like the use stereo cameras.

Radar based AI detection and, and some of those things, like if you talk with some ornithologists for the big OEMs and stuff, they’ve been dabbling in those things. Like I dabbled in a project without a DTU, uh, a while back and it, but it wasn’t large scale done like this. A [00:06:00] particular win this study in the United States is there’s been this battle in the United States about what birds and what, you know, raptors or these things are controlled or should have, um, controls over them by the governments for wind installations.

The big one right now is US Fish and Wildlife Service, uh, controls raptors, right? So that’s your eagle’s, owls, hawks, those kind of things. So they’ll map out the nests and you can only go in certain areas, uh, or build in certain areas depending on when their mating seasons are. And they put mild buffers on some of them.

It’s pretty crazy. Um, but the one rule in the United States, it’s been kind of floated out there, like, we’re gonna throw this in your face, wind industry. Is the Federal Migratory Bird Act, which is also how they regulate all like the, the hunting seasons. So it’s not, it’s the reason that the migratory birds are controlled by the federal government as opposed to state governments is because they cross state lines.

And if we can [00:07:00] prove now via this study that wind farms are not affecting these migratory bird patterns or causing deaths, then it keeps the feds out of our, you know, out of the permitting process for. For birds,

Rosemary Barnes: but I’m not sure this is really gonna change that much in terms of the environmental approvals that you need to do because it’s a, you know, a general, a general thing with a general, um, statistical population doesn’t look at a specific wind farm with a specific bird and you’re still need to go.

You’re still going to have to need to look at that every time you’re planning an actual wind farm. That’s it’s fair.

Yolanda Padron: And it’s funny sometimes how people choose what they care or don’t care about. I know living in a high rise, birds will hit the window like a few a month. And obviously they will pass away from impact and the building’s not going anywhere.

Just like a turbine’s not going anywhere. And I’ve never had anybody complain to [00:08:00] me about living and condoning high rises because of how they kill the birds. And I’ve had people complain to me about wind turbines killing the birds. It’s like, well, they’re just there.

Joel Saxum: If we’re, if we’re talking about energy production, the, if everybody remembers the deep water horizon oil spill 2010 in the Gulf of Mexico.

That oil spill killed between 801.2 million birds. Just that one.

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Allen Hall: well in the high desert of Central New Mexico, near a lot of what were ghost towns that were abandoned during the Great Depression.

If there is a flurry of activity pattern, energy sunzi, a project is near completion after 20 years of planning and permitting. When. It’s supposed to be finished in 2026. It’ll be the largest renewable energy project in the Western hemisphere. More than 900 turbines spread across multiple counties. A 550 mile transmission line stretching to Arizona and then onward to California, and $11 billion bet that’s being made on American wind.

Now, Joel, it’s a kind of a combination of two OEMs there, Vestus and ge. The pace of building has been really rapid over the last six, eight months from what I can [00:10:00] tell.

Joel Saxum: Yeah. We have talked to multiple ISPs, EPC contractors. Um, of course we know some of the engineers involved in building a thing on the pattern side.

Right. But this sheer size of this thing, right, it’s, it is three and a half gigawatts, right? You’re talking 900 turbines and, and so big that one OEM really couldn’t, I mean, it’s a, it’s a risk hedge, right? But couldn’t fulfill the order. So you have massive ge tur set of turbines out there. Massive set of vestas turbines out there.

And I think one thing that’s not to be missed on this project as well is that transmission line, that high voltage transmission line that’s feeding this thing. Because that’s what we need, right? That was when we built, started building up big time in Texas, the cre, the crest lines that were built to bring all of that wind energy to the major cities in Texas.

That was a huge part of it. And we have seen over the last six months, we have seen loans canceled, uh, permits being pulled and like troubles being in hurdles, being thrown up in the face of a lot of these transmission lines that are planned. [00:11:00] These big ones in the states. And that’s what we need for energy security in the future, is these big transmission lines to go.

So we can get some of this generation to, uh, to the market, get electrons flowing into homes and into industry. But this thing here, man, um, I know we’ve been talking about Sunz, the Sunz project, uh, and all the people involved in it, in the wind industry for a, what, two, three years now? Oh, at least. Yeah.

It’s been in planning and development stage for much longer than that. But the. The, the big bet. I like it. Um, bringing a lot of, um, bringing a lot of economic opportunity to New Mexico, right? A place that, uh, if you’ve driven across New Mexico lately, it needs it in a dire way. Uh, and this is how wind energy can bring a lot of, uh, economic boom to places that, uh, hadn’t had it in the past.

Allen Hall: And this being the largest project to date, there’s a, I think a couple more than a pipeline that could be larger if they get moving on them. We see another project like this five years [00:12:00] from now, or we think we’re gonna scale down and stay in the gigawatt range just because of the scale and the things that Sunzi went through.

Joel Saxum: We have the choke chair, Sierra Madre project up in Wyoming that’s been chugging the Anschutz Corporation’s been pushing that thing for a long time. That’s, that’s along the same size of this unit. Um, and it’s the same thing. It’s, it’s kind of hinged on, I mean, there’s permitting issues, but it’s hinged on a transmission line being built.

I think that one’s like 700. 50 miles of transmission. That’s supposed to be, it’s like Wyoming all the way down to Las Vegas. That project is sitting out there. Um, it’s hard to build something of that size in, like say the wind corridor, the Texas, Oklahoma, uh, you know, all the way up to the Dakotas, just simply because of the massive amount of landowners and public agencies involved in those things.

It’s a bit easier when you get out West New Mexico. Um, I could see something like this happening possibly in Nevada. At some point in time to feed that California [00:13:00] side of things, right? But they’re doing massive solar farms out there. Same kind of concept. Um, I, I think that, um, I would love to see something like this happen, but to invest that kind of capital, you’ve got to have some kind of ITC credits going for you.

Um, otherwise, I mean, $11 billion is, that’s a lot of money

Allen Hall: since Zia will have PTC. Which is a huge driver about the economics for the entire project.

Joel Saxum: Yeah. But you’re also seeing at the same time, just because of the volatility of what’s happening in the states wind wise, uh, there was a big article out today of someone who got wind that EDF may be selling its entire

Allen Hall: US onshore renewable operation or US renewable operation.

That was Wood Mac that. Put that out. And I’m still not sure that’s a hundred percent reliable, but they have been 50% for sale for a while. Everybody, I think everybody knew that.

Joel Saxum: Yeah. I don’t know if it’s a hundred percent reliable as well. I would agree with you there. However, there’s, it’s the [00:14:00] same thought process of European company pulling outta the United States.

That’s where a lot of the renewable energy capital is, or it has been fed to a lot of that capital comes from Canada and other places too. Right. But that’s where it’s been fed through. Um, but you’re starting to see some, some. Uh, purchasing some acquisitions, a little bit of selling and buying here and there.

I don’t, I don’t think that there’s, uh, massive ones on the horizon. That’s just my opinion though.

Allen Hall: Well, won’t the massive ones be offshore if we ever get back to it?

Joel Saxum: Yeah, you would think so, right? But I, that’s gonna take a, uh, an administration change. I mean the, the, all that stuff you’d see out in California, like when we were originally seeing the leases come out and we were like, oh, great.

More offshore opportunity. Ah, but it’s California, so it’ll be kind of tough. It probably won’t be till 20 32, 20, something like that. I don’t think we’ll see possibly California offshore wind until 2040 if we’re lucky.

Allen Hall: Joel, what were the two wind turbines selected for Sunz? They were both new models, right?

One from Renova and then the other one from [00:15:00] Vestas,

Joel Saxum: so the Vestas was 242 V, 1 63, 4 0.5 megawatts machines, and the, and the GE Renova. Just so we get, make sure I get clarity on this. 674 of its three. They were 3.6, but they’re 3.61 50 fours.

Allen Hall: Okay. So both turbine types are relatively new. New to the manufacturer.

CZ has two new turbines styles on the site.

Joel Saxum: Yeah, we were told that when they were originally like getting delivered, that they didn’t have type certificates yet. That’s how new they were.

Allen Hall: So Yolanda. As Sania starts to turn on, what are things that they need to be aware of blade wise,

Yolanda Padron: besides the lightning and the dust in New Mexico?

It’s probably gonna tip them. I don’t know exactly what they’re counting with as far as leading edge protection goes.

Allen Hall: Pattern usually doesn’t, uh, have a full service agreement. Joel, do you remember if that was an FSA? I don’t think so.

Joel Saxum: I would say [00:16:00] because those are Vestas turbines on the one that, yes, Vestas really doesn’t sell a turbine without it.

Knowing internally how big patterns engineering group are, I don’t know if they can completely take on the operations of a thousand more turbine, 900 more turbines overnight. Right? So I think that there is gonna be some OE EMM involvement in these things, uh, simply to be at that scale as well. I don’t know of anywhere else with a 1 54 install a GE 1 54.

So the things that I wouldn’t looking out is the. It’s the brand new type stuff, right? Like do internal inspections when they’re on the ground. You don’t know what kind of condition these things are in, what, you know, what is the, you haven’t, nobody’s seen them. Like you’re the first ones to get to get your hands on these things.

Yolanda Padron: Yeah, I think they’re definitely gonna have to go with some sort of consulting or something externally as far as what exactly they’re dealing with. I know, Rosemary, you’ve touched on it a lot, right about. [00:17:00] How the changing the blade types and changing the turbines every x amount of years is really not conducive to, to being able to repeat the same results.

And if you’re having that for hundreds of turbines at a new site that you’ve already had so much time and money invested in creating, it’ll, it’s, it’s a big undertaking.

Rosemary Barnes: It’s really interesting because. When you have such a large wind farm be, I’m assuming one of the first wind farms may be the first to get this new turbine types, then if there’s a serial defect, it’s gonna be very obvious.

’cause with smaller wind farms, one of the problems is that, uh, the numbers are too small to definitively say whether something is, um, serial or just random bad luck. Um, but when you get. So how many wind turbines is it?

Joel Saxum: Almost a thousand total. It’s [00:18:00] 674 GE turbines and 242 Vesta turbines.

Rosemary Barnes: You can do statistics on that kind of a population and this area.

I mean, there’s lightning there, right? Like this is not an area where you’re not gonna see lightning. You know, in know the first couple of years, like there, there will be. Hundreds of turbines damaged by lightning in the, the first couple of years I would suggest, um, or, you know, maybe not. Maybe the LPS are so, so great that that doesn’t happen.

But, you know, the typical standard of LPS would mean that, you know, even if you only see, say we see 10 strikes per turbine to year and you get a 2% damage rate, that is, you know, lots of, lots of individual instances of blade damage, even if everything works as it should according to certification. And if it doesn’t, if you see a 10% damage rate or something from those strikes, then you are going to know that, you know, the, um, LPS is not performing the way that the standard says that it should.

It’s not like that’s a slam dunk for, um, [00:19:00] proving that the design was not sufficient or the certification wasn’t correct. It’s always really, really tricky. My recommendation would be to make sure that you are monitoring the lightning strikes, so you know exactly which turbine is struck and when, and then go inspect them and see the damage.

Ideally, you’re also gonna be measuring some of the characteristics of the lightning as well. But you do that from day one. Then if there is a problem, then you’re at least gonna have enough information within the, um, you know, the serial defect liability period to be able to do something about it.

Joel Saxum: Let me ask you a question on that, on just the, that lightning monitoring piece then.

So this is something that’s just, it’s of course we do this all the time, but this is boiling up in the thing. How do you, how do you monitor for lightning on 916 turbines? Probably spread, spread across. 200 square miles.

Rosemary Barnes: Well, there’s, there’s heaps of different ways that you can do it. Um, so I mean, you can do remote, remote lightning detection, which is [00:20:00] not good enough.

Then there are a range of different technologies that you can install in the, um, turbines. Um, the most simple and longest standing solution was a lightning cart, which is installed on the down conductor at the blade route. That will just tell you the amplitude of the biggest strike that that turbine has ever seen when it’s red.

I have literally never seen a case where the lightning card definitively or even provided useful evidence one way or another when there’s a, a dispute about lightning. So then you move on to solutions that, uh, um. Measuring they use, uh, Alan, you’re the electrical engineer, but they, they use the, the principle that when there’s a large current flowing, then it also induces a magnetic field.

And then you can use that to make a, a, a change and read characteristics about it. So you can tell, um, well first of all, that that turbine was definitely struck. So there are simple systems that can do that quite cheaply. The OGs ping [00:21:00] sensor, does that really cost effectively? Um, and then OG Ping. Phoenix Contact and Polytech all have a different product.

Um, all have their own products that can tell you the charge, the duration, the um, polarity or the, yeah, the, the, if it’s a positive or a negative strike, um, yeah, rise time, things like that. Um, about the strike, that’s probably, probably, you don’t. Need to go to that extent. Um, I would say just knowing definitively which turbine was struck and when is gonna give you what you need to be able to establish what kind of a problem or if you have a problem and what kind of a problem it is.

Joel Saxum: I think that like an important one there too is like, uh, so I know that Vest is in a lot of their FSA contracts will say if it’s struck by lightning, we have 48 or 72 hours to inspect it. Right. And when you’re talking something of this scale, 916 turbines out there, like if there’s a lightning storm, like [00:22:00]we’ve been watching, we watch a lot of lightning storms come through, uh, certain wind farms that we’re working with.

And you see 20, 30, 40 turbines get struck. Now if a storm comes through the middle of this wind farm, you’re gonna have 200 turbines get struck. How in the hell do you go out without ha Like you need to have something that can narrow you down to exactly the turbines that we’re struck. That being said that next morning or over the next two days, you need to deploy like 10 people in trucks to drive around and go look at these things.

That’s gonna be a massive problem. Pattern has about 3000 turbines, I think in their portfolio, and they, so they’re, they’re familiar with lightning issues and how things happen, but something at this scale when it’s just like so peaky, right? ’cause a storm isn’t through every night, so you don’t have that need to go and inspect things.

But when you do. That is gonna be a massive undertaking. ’cause you gotta get people out there to literally like, at a minimum, binocular these things to make sure there isn’t any damage on ’em. And it’s gonna be, there’s gonna be storms where hundreds of turbines get hit.

Rosemary Barnes: Yeah, well [00:23:00] those three companies, those three products that I mentioned are aiming to get around that.

I mean, it will depend how contracts are worded. I know in Australia it is not the norm to check for lightning ever. So if the contract says someone has to, you know, use human eyeballs to verify lightning damage or not, then. That’s, you know, that’s what has to happen. But all of these technologies do aim to offer a way that you wouldn’t have to inspect every single one.

So Polytech is using, um, different lightning characteristics and then they’ve got an algorithm which they say will learn, um, which types of strike cause damage that could. Potentially progress to catastrophic damage. Um, and then the other one that is interesting is the eLog Ping solution because they’ve also got the, um, damage monitoring.

That’s their original aim of their product, was that if there’s a damage on the blade tip, say it’s been punctured by lightning, it, it actually makes a noise. Like it makes a whistle and they listen out for that. So if you combine the [00:24:00]lightning detection and the, um, like blade. Tip structure monitoring from Ping, then you can get a good idea of which ones are damaged.

Like if it’s damaged badly enough to fail, it is almost certainly gonna be making a noise that the ping can, um, detect

Allen Hall: as wind energy professionals. Staying informed is crucial, and let’s face it, d. That’s why the Uptime podcast recommends PES Wind Magazine. PES Wind offers a diverse range of in-depth articles and expert insights that dive into the most pressing issues facing our energy future.

Whether you’re an industry veteran or new to wind, PES Wind has the high quality content you need. Don’t miss out. Visit PE ps win.com today and this quarter’s PES WIN Magazine. There’s a lot of great articles, and as we roll into December. You’ll have time to sit down and read them. You can download a free copy@pswin.com.

And there’s a, a really interesting article about [00:25:00] offshore, and there’s a number of articles about offshore this quarter. Well, two Dutch companies developed a solution to really one of the industry’s most persistent headaches. And when it’s flange alignment. So when you’re trying to connect the transition piece to the mono paddle out in the water, it’s not really easy to do.

Uh. So PES interviewed, uh, Ontech and Dutch heavy lift consultants to explain their flange alignment system known as FAS. And it started when a turbine installation needed a safer, faster way to try to align these two pieces. So if you can think about the amount of steel we’re talking about, these are really massive pieces you’re trying to line and put bolts in, not easy to do out in the ocean.

Uh, so what this new device can do is it can align the flanges in a couple of minutes. It can reshape deformed, flanges and Joel, as you know, everything offshore can get dinged warped. That’s pretty easy to do, so you don’t want that when you have a, a heavily loaded, bolted joint, like those flanges to be [00:26:00] perfectly, uh, smooth to one another and, and tight.

So these two companies, Amek and Dutch heavy Lifting consultants have come up with some pretty cool technology to speed up. Installations of wind turbines.

Joel Saxum: Yeah, I would say anybody who’s interested in wind, offshore wind, any of that sort, and you have a little bit of an engineering mind or an engineering, uh, quirk in your mind.

As, as I think we said earlier in the episode today, engineering nerds. Um, I would encourage you to go and look at some heavy lift operations offshore, whether it is offshore wind, offshore oil and gas, offshore construction of any time or any type even pipe lay operations and stuff. Just to take, just to take in the, the sheer scale.

At how, uh, at how these things are being done and how difficult that would be to manage. Think about the just tons and tons of steel and, uh, trying to put these pieces together and these different things. And then remember that these vessels are thousands of dollars, sometimes a minute for how specialized they are.

Right? So a lot of money gets put into [00:27:00] how the, like when we’re putting monopiles in that these transit transition pieces get put on. A lot of money has been spent on. The ver like technology to get, make sure they’re super, super tight tolerances on the verticality of those when they’re driving the actual piles in.

And then you’re doing that offshore in a nasty environment, sometimes from a jack up vessel, sometimes not from a jack vessel, sometimes from a mor or like a, you know, a pseudo mor vessel on, uh. Dynamic positioning systems, and then you’re swinging these big things with cranes and all this stuff, like, it’s just a crazy amount of engineering eng engineering and operational knowledge that goes into making this stuff happen.

And if you make one little mistake, all of a sudden that piece can be useless. Right? Like I’ve been a part of, of heavy offshore lifting for oil and gas where they’ve. It’s built a piece on shore, got it out to the vessel, went to go put it off sub sea in 2000 meters of water, lowered it all the way down there and it didn’t fit like you just burned [00:28:00] hundreds and hundreds and thousands of millions of dollars in time.

So this kind of technology that Anima Tech is putting out in Dutch Heavy Lift consultants. This is the key to making sure that these offshore operations go well. So kudos to these guys for solve for seeing a problem and solving a problem with a real solution. Uh, instead of just kind of like dreaming things up, making something happen here.

I’d like to see it.

Allen Hall: Check out that article and many more in this quarter’s. PES Wind Magazine downloaded free copy@pswind.com. Well, Yolanda, as we know, everybody’s out with Sky Specs, uh, doing blade inspections, and so many turbines have issues this year. A lot of hail damage, a lot of lightning damage and some serial defects from what I can tell.

Uh, we’re, we’re getting to that crazy season where we’re trying to get ready for next year and prioritize. This is the time to call C-I-C-N-D-T and actually take a deep hard look at some of this damage, particularly at the blade root area. We’ve seen a lot more of that where, [00:29:00] uh, there’s been failures of some blades at the root where the bolt connection is.

So you’re gonna have to get some NDT done. Boy, oh boy, you better get C-I-C-N-D-T booked up or get them on the phone because they’re getting really busy.

Yolanda Padron: Yeah, you definitely need to schedule something. Make sure that you know at least where you stand, right? Be because imagine going into try to fix something and just have a hammer and then close your eyes and then see what you can fix.

That way, like sometimes it feels like when you’re in operations, if you don’t have the proper. The proper inspections done, which sometimes there’s, there’s not enough budget for, or appetite or knowledge, um, in some of these projects to have early on. You come in and just, you, you see the end result of failure modes and you might see something that’s really, really expensive to fix now.

Or you might think of, oh, this problem happened at X, Y, Z. [00:30:00] Site, so it’ll probably happen here. That’s not necessarily the case. So getting someone like NDT to be able to come in and actually tell you this is what’s going on in your site, and these are the potential failure modes that you’re going to see based on what you’re getting and this is what will probably happen, or this is what is happening over time in your site, is a lot more indicative to be able to solve those problems faster and way.

More way, in a way less expensive manner than if you were to go in and just try to fix everything reactively. You know, if you have half a bond line missing. Then later you, your blade breaks. It’s like, well, I mean, you, you could, you could have seen it, you could have prevented it. You could have saved that blade and saved yourself millions and millions of dollars and, and so much more money in downtime.

Joel Saxum: Yeah. The first time I ran into Jeremy Hess and the C-A-C-N-D team was actually on an insurance project where it was Yolanda, like you said, like [00:31:00] they let it go. The, the operator and the OEM let it go way too long, and all of a sudden they had a, like wind farm wide shutdown costing them millions in production.

Uh, to find these, these issues that, uh, could have been found in a different manner when you talk to the team over there. Um, why we like to recommend them from the podcast is Jeremy has an answer for everything. He’s been around the world. He’s worked in multiple industries, aerospace, race, cars, sailboats, you name it.

Um, he’s been a client to almost everybody, you know, in the wind industry, all the OEMs, right? So he knows the, the issues. He has the right tool sets. To dive into them. You, you may not know, not, you don’t need to be an NDT expert to be able to have a conversation because he will coach you through, okay, here you have this problem.

Alright, this is how we would look at it. This is how we would solve it. Here’s how you would monitor for it, and then this is how you would, you know, possibly fix it. Or this is what the, the solution looks like. Um, because I think that’s one of the [00:32:00] hurdles to the industry with NDT projects is people just don’t.

Know what’s available, what’s out there, what they can see, what they, you know, the issues that they might be able to uncover, like you said, Yolanda. So, um, we encourage, um, anybody that says, Hey, do you know anybody in NDT? Yeah, it’s Jeremy Hanks and the C-I-C-N-D-T team. Call ’em up. They’ve got the solutions, they’ll help you out.

Allen Hall: That wraps up another episode of the Uptime Wind Energy Podcast. If today’s discussion sparked any questions or ideas, we’d love to hear from you. Just reach out to us on LinkedIn and don’t forget to subscribe so 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 next week on the Uptime Wind Energy [00:33:00] Podcast.

German Bird Study Finds 99% Avoid Turbines, SunZia Progress

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A Lesson from the Early 20th Century

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My maternal grandfather was born in southeastern Pennsylvania in 1903 and told me when I was a boy that in the 1920s, times were so good that saloon owners would offer a free lunch, consisting of bread and butter, cheese, cold cuts, pickles and the like. “Sure, they were hoping you’d buy a glass of beer for a nickel, but they really didn’t mind if you didn’t and simply scarfed down a free sandwich.”

He went on to tell me that nowadays, there’s a popular slogan: There’s no such thing as a free lunch, “but believe me, there was at the time.”

From today’s perspective of greed and selfishness, this whole story sounds like a fairy tale.  Corporations and the congresspeople they own want one thing: to suck the life out of us.

A Lesson from the Early 20th Century

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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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