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Hitachi Energy Leads the Energy Transition

Laura Fleming and Alfredo Parres from Hitachi Energy dive into the critical challenges of integrating renewable energy, particularly offshore wind power, into the UK grid. They explore innovative solutions, including HVDC technology and digital advancements, that are driving efficient, reliable energy distribution and shaping the future of the global energy landscape. With Laura’s over 25 years of experience in the energy sector and Alfredo’s long history in renewables, the two give insights into how Hitachi is making the energy transition possible.

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Allen Hall: With power grids adapting to accommodate growing renewable energy, the challenges of integration had never been more critical. This week, we speak with Alfredo Parres group, senior Vice President and head of Renewables at Hitachi Energy. And Laura Fleming, country managing director at Hitachi Energy UK and Ireland.

Together, they explain how Hitachi’s technology is enabling efficient, reliable connections between massive wind farms and our existing electrical infrastructure. This is a great interview. Stay tuned.

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

Powering tomorrow.

Allen Hall: Laura and Alfredo, welcome to the podcast.

Laura Flemming: Glad to be here.

Alfredo Parres: Hey, huh.

Allen Hall: How are you? Laura, let’s start with you because I’ve watched a number of your interviews on YouTube and there’s just a lot happening within Hitachi. What are some of the main challenges in the UK facing sort of the renewable energy grid and all of the particularly wind power, which is what we’re focused on.

There’s a lot of wind power offshore being deployed in the UK at the minute. How is a Hitachi trying to handle that and distribute that energy?

Laura Flemming: Yeah. Thank you for the question. And uh, it’s a super exciting time, as you’re saying in in the uk energy space. And maybe just to explain briefly what is going on the UK.

At the moment, it’s very hard at work to decarbonize the electricity grid. It’s actually planning to be fully carbon zero by 2030. That’s only in five years time now. And that’s obviously a very big job. What we’re doing in order to reach that as a country is switching away from from carbon sources.

And so about six weeks ago. We switched off our last coal-fired power station, for example. But of course we still need energy and we still need a lot of electricity. So what we’re doing instead is building out a lot of renewable energy predominantly offshore wind because that allows us to produce vast amounts of electricity quickly cheaply and sustainably.

The result of all of that is that actually we’re producing electricity in very different places than that we used to. So offshore wind, obviously produced in the sea, mainly in the north of Scotland particularly in Scotland. But the demand centers are all in the s of the country, predominantly around London and Birmingham areas.

So we needing to transport this electricity around the system in a very different way. And all of that is triggering lots of grid reinforcements requiring to be done as well. So, and obviously without that grid, we can’t move around this this new electricity from the generation source to the to the demand centers in a very efficient and also in a reliable way.

And also making sure that we don’t have too many losses on the system. So this is a huge task. The role that Hitachi energy in is playing in all of this is to ensure that a large number of these offshore wind projects can be connected to the UK grid. We are also supporting the transmission owners to help build out the grid, to make it more flexible, more reliable, and more efficient.

And then we’re also supporting, for example, onshore and solar generators connecting their projects in via, via substations, et cetera.

Allen Hall: Alfredo, what happens if the, this interconnection doesn’t happen to the UK economy and more? Wider impacts in terms of Europe. It does seem Laura has mentioned a lot of the energy sources are coming from remote places, but the power is being used in kind of the big places.

Paris, London in Germany, there’s just big power usage areas. If we don’t connect them, what’s the outcome of that?

Alfredo Parres: Yeah. I think it’s fair to say that it’s difficult to think about an energy transition without grids. Grids, electricity is about to be everything as we move on. And we need a lot of those.

And grids that’s in many places are also oldish. Depending where you are on the world can have assets where that are pretty old. So we need to pay attention to that. The good news on this, a Noel, as I like to say, is that I see that. The conversation on grid has evolved drastically, compared to a to previous years.

I see the conversation as has already evolved a lot, typically in my early days in, in this business it’s a few years. We had to educate people, educate governments on the importance of grids, anticipating what was coming, or it was a lot of education to be done. These days, you go to any conference, any civil servant speaks about grids as well as I do.

So that means they, they are aware, they’ve educated themselves, they know what they’re talking about. And they the connections, I think in Europe, if you think about the grid action plan that the commission has put together is looking at implementing. I think that speaks what I’m mentioning here, the plans are there and the options to do things are huge.

From increasing capacity or improving the usage of the existing grids. That’s the first step we can do. Technologies are there to do that, building new grids and planning the development of new grids. There are things that are doing, so in a nutshell, Alan, and we can go in further details in the conversation, there is no energy transition without greats good news or politicians or governments.

Got it. We start putting the real

Joel Saxum: actions required, I think to speak on this problem here with grids and integration with renewables. Again, for the energy transitions. Someone once said there’ll be no transition without transmission. I like that statement. But to speak on that issue more when these, when the grid that we’re, that we’ve lived with for, a long time it was originally developed. Most of that was with this consistent power delivery to it, right? It was coal fired power plants and other sources where it was consistent. And now when we add renewables to the mix, and they are by nature, intermittent, whether it’s solar or wind or however and people are trying to control that now as we move forward with battery storage and things.

It complicates that grid question as well because now we’re saying, Hey, we need to upgrade the grid, but we also need to upgrade and future proof the grid, and I think that’s a very important statement there as well. And Hitachi, that’s what you guys are doing. You’ve got loads of people working on these problems to solve this intermittent delivery issues.

And that’s hand in hand with the contemporary term, I guess is the smart grid. So Alfredo, I’d like to ask you this question. At what point in time did you start to see, the stakeholders that can make some of these decisions around the grid start to open their eyes to the difference that we need to future proof this?

The energy mix looks different, and if we don’t fix this, we’re gonna really run into issues

Alfredo Parres: beside grids. We are spending a lot of time to tell exactly about that. It’s not just the grid, it’s the complexity of the power system we are developing. We are going to manage intermittent source of generation.

Different side of science type of generation based on power electronics, which basically says it’s a generation profile that is much more volatile with less inertia. We will have to manage all those elements in a harmonious way because we want to keep a sustainable power system at power safe and save power system.

So the education is happening and we see the message getting there. As I said, you think from a planning perspective and everything start with planning. There’s no point to try to solve it if you don’t have a visibility 5, 10, 15, 20 years ahead to see what are we going to need? What are the investments we going to need?

What is infras going to need? And that is happening. We still, of course, need to always to improve, and that’s what we’re talking right now with the authorities, know how we can improve the planning piece on the technology side, we tell them technology exists to manage this complexity we’re going to face.

Intermittency is not the end of the world. It should not stop penetration of renewables. We can bring much more into the system and technologies are there to help us for electronics. These things we use for batteries management to use fax, all those system, I have to stabilize grids to be the HVDC connections.

Essential to keep the stability, to keep this flow of energy oriented in different directions. Digital, absolutely key. Also because digital will help us to manage this complexity we’re facing. From a demand perspective, from a generation perspective, to operate, to maintain, the digital piece absolutely key.

And that’s a not so easy story to get through because digital, not everybody understand what it means. For real. We are Hitachi, we make it as a party for us, no to tell how digital is real and can help us to to address our challenges. No.

Allen Hall: Laura, I want to use the Eastern GreenLake two as our test case here to walk through some of the things Hitachi is doing.

So the Eastern GreenLake two is A-H-V-D-C project, two gigawatts that is being transmitted from Northern Scotland down to England offshore, and the this distance is 440 kilometers, which in America terms is about 250 plus miles. That’s a long way for an HVE DC cable. The complexities of that project have to be enormous.

How does Hitachi fit into that infrastructure project?

Laura Flemming: Yeah, it’s a really good question. And the exactly as you say, the Eastern Greenland project is a is massive in terms of scale. But it’s also groundbreaking in terms of what it’s trying to do. It it will be collecting the power from a number of offshore wind farms and renewable generation capacity from the north of Scotland collected at this this, really large substation that’s going to be built in in the north of Scotland, as you say.

And then to be transporting that power to the somewhere in the middle of England. Via an offshore connection. So rather than transporting that power via, multiple pylons and multiple cables that going onshore overground as we would’ve done in the maybe in the good old days.

All of this power is being transported offshore. And that has a number, a number of advantages. In terms of connection with the communities in terms of environmental impact in terms of, being able to cross communities, et cetera. But it also has an added benefit because actually using A three DC over a large distance also means that, the energy losses will be significantly reduced.

So what is it that Hitachi Energy is doing? We’re providing both the on and offshore substations that’s basically can, making the connection. So we don’t do the cables, but we do, we effectively provide the plug, right? That allows this energy to be collected and to be put into the cables.

And then to be taken out of the cables and then put into the grid so it can actually be usefully used. And what that’s actually allowing, the UK electricity system operator to do is manage the power flows around the country. So really providing that security and that stabilization delivering power as and when they need it but also as and when it is being produced and really optimizing.

What we’re producing as a country. And as you say, also that helps us manage the the renewable resource, which is sometimes, is it is intermittent. So there’s a lot more work around digitalization power electronics going on in the background to to manage those flows. At any given time of the day, we can still keep the lights on.

Allen Hall: I want to dig into that a little bit because we use HV dc you just throw on that term. It’s we just use HVDC, but that is really complicated. The power electronics that are going into these devices are revolutionary. To do something at a high voltage DC wise in the electronics to make that happen are truly incredible.

And to do it bidirectionally, you can move power around as needed because of the renewable energy factor where sometimes as the wind’s not blowing, sometimes it’s not as sunny out. You need to redirect where energy is flowing. H Feed DC gives you that. But how much infrastructure on the Hitachi side is.

Dedicated to HVDC and the software and all the control systems to create this grid.

Alfredo Parres: So we just celebrated 75 years of anniversary for the technology. We started back in the early fifties. So that tells is a young, old technology we are talking about here, the last version or the last technology we’re using.

The VSC variable source converter version of it is a bit younger. No, but this is a technology that has been proving by the years benefits. No you mentioned it, long distance transmission, bidirectional flow, but there are a lot of orders benefits, no, not the least, the low losses. No.

We use it because we reduce drastically the losses of our lung transmission. Plus the support we can give to the grid to which the HBC link is connected. So actually this link is supporting the stability of the grid. And in these days with the high penetration renewables, that’s extremely important just to tell.

The benefits are absolutely phenomenal. And it’s true that with the emergence and the boom on around offshore wind, the technologies is facing fantastic times. And for us it’s really where we are putting a lot of our investments, a lot of our people we’re talking about, of thousands of people are being hired to support this business.

Among the six billions we are investing these days, a lot is going in manufacturing of new valve new valve manufacturings, hiring new engineers to go in all different centers. And in Sweden, ru where we have, the capital, the place where the technology was born. Are we talking about the middle of Sweden in a very nice natural place, but not necessarily the place you would go for to in business, having hundreds of people going there, finding the, finding themselves comfortable with a clean mission, which is to accelerate this energy, trans transition and working with, for leading company, they got education.

They work in a diverse environment because of course we got people coming from all over the world. They find themselves and they can law. So really I think HVDC is leaving extraordinary times. We see that all suppliers knowing this technology investing. So we are not the only ones, which is good also because that’s, the demand is huge.

We need. Everybody to contribute, and we need then society to understand the benefits now of the technology.

Joel Saxum: So HVDC in my mind, I think would it’s going to be as the grid gets newer, fresher, more innovative, and we start putting some money into it. You’re starting to see some of that here in the states.

Couple saw a couple of reports in the last week of some big money rolling into it. HVDC to me should start to be a much broader part of that energy grid as you guys are focusing a lot of effort into it with employees and investment. How mu, how much of a percentage growth do you think, and I know that’s a pointed question, do you see an HVDC versus in the past?

Laura Flemming: If I can maybe comment on in terms of the growth that we see in the uk, we’re seeing the UK really moving for maybe doing. One HVDC project that, as a country, right? Not necessarily as Hitachi Energy by themselves, but as a country we’re really moving from doing one of these projects a year to doing, multiple, like three or four, maybe even more projects a year.

So the growth is, not just huge, it’s exponential. And as Alfredo was saying earlier, that’s really why we’re, we’re resourcing up, we’re hiring, thousands of people. To be able to work on HVDC solutions around the world. And because it’s not just the manufacturing of the converters and all of the other equipments that goes onto the, into the platforms and into the substations.

There’s a huge amount of engineering, of front end engineering that and design that needs to be done. Before you can start building such a project and really planning all of that in, in a strategic way into the overall grid is really crucial. And I think this is really the interesting thing that we’re seeing in the UK where we’ve really, moved from a connect and manage sort of approach.

So we’ll connect it when there is a need for it, and we know we have everything ready. To, know, let’s actually plan for, let’s plan for the future and we’re going to see what we need in the future, and we’re going to get ready and build that because we know that the generation and the demand will be coming.

And that’s when solutions such as HVDC become really critical. And it also depends on distance, right? So the distance is really a big element in HVDC. So anything. Over 120, 30 miles away. Is really going to be beneficial to use HVDC

Allen Hall: and Hitachi touches. Almost everyone’s lives in Europe and the United States.

You may not realize that, but Hitachi’s big on H-V-A-C-H-V-D-C and on the monitoring and support side they’re involved everywhere. And maybe touch upon Alfredo what. Hitachi is doing after the sale, after the grid’s been installed. There’s a lot of monitoring, support and software that goes on after the grid has been connected, right?

Absolutely.

Alfredo Parres: And welcome to, to, to this new world know, and I mentioned it before, know, which is digital, I mean with our new owners, as I guess more many people know by, by now. As a former a PB now owned by Hitachi. We have new owners that believe deeply in, in the role of digital and they invest heavily as a business itself.

And we are enjoying the benefits of being part of this larger corporation and developing the, those solutions of the future based on the core knowledge we do have. ’cause at the end, what makes a difference in digital is the understanding of the product and the process and the technology, which we master in Hitachi.

And you put a layer of digital on top of that. Which is the embedded digital solution we have in product solutions plus the layers of digital. You have to control and operate all those assets. Bingo. Then you start having comprehensive solutions that bring value to customers. No, and that’s where we are heading for the train has left the station ready for a while now.

We are not so starting now but the journey is still long to go until we reach full benefits. And Forest Service is going to be a huge focus area because we are sitting not only on a huge install base, you think about what a hundred years working on, on, on the market with millions of equipments out there that we can serve and we to serve more of them, but the requirements really come higher as the system will become more complex, more fragile.

So we need to be able to react quickly. But also we have to react to the environment, conditions that we are facing. Going to tell about all the climate incidents that we’re facing. That’s part also of operating an asset. No. And here too, a digital play, a big role or to not only anticipate forecasting evidence that can happen.

Get prepared with your plans. Get prepared with your actions to add quickly. Definitely for us is a critical area.

Allen Hall: Can we discuss the order book for Hitachi at a top level A little bit? How busy is Hitachi right now on orders and my guess is that your phone is ringing all the time. People trying to get orders in for HVDC, even HVAC at the minute.

How busy are you?

Laura Flemming: Yeah, now I can comment from a UK and Ireland perspective, so no, we’re very busy. And obviously that is wonderful. What’s really important for us is to ensure how do we bring the best of what Hitachi energy has got offer to our customers?

And therefore we have changed slightly the approach in which we are working with customers really working in programs. And frameworks and again, in in a systematic and strategic way. And that is a number of benefits. Yes, it allows us to understand, what work is coming. And that is really important for us, for our production planning, for making the investments that we talked about earlier.

And also for hiring people because the biggest. Obstacle that we have in in this energy transition is actually people we need. We need to train, we need to hire, we need to manage a vast amount of new people coming into the industry, not just in Hitachi energy, but into the industry.

So we’re really facing facing quite an uphill battle there. And so yeah, having that visibility requires us to, and allows us to plan in advance, there’s another very important aspect to all of this as well is that when we know what our customers are looking to do over the next few years or so, we can start working and engaging with them at a much earlier stage in their project.

That will allow us to help them standardize some of the solutions and that standardization will allow us to speed up, it’ll allow us to work more safely. It will allow us to, move from site to site knowing the issues that can appear on sites and actually be able to anticipate on the, on those in advance.

So yeah, that early engagement and a strategic approach to, to the order book, as you were saying earlier is super critical for us, but also ultimately for the customer and for the overall, for the greater good.

Allen Hall: Let’s talk about that variations that you see on orders and everybody when you hear about the power grid, a lot of operators, owners want a very specific set of parameters.

They don’t want to order a generic piece of equipment, but that’s a huge problem for the grid and for the manufacturing and planning. Are you starting to see a little more standardization as. The demand goes up that maybe I can use a slightly better HVD system that’s standardized for my project instead of having a tailored one for my specific needs.

Alfredo Parres: I think it’s a moving reality. And, and we cannot say we are there. Of course, we cannot say we are there, but we mentioned this always on the different ways. No, now I refer to the first one. Or if you have a frame agreement, if you work on a portfolio of project. Here we go.

That’s what we got. That’s what we did with the transmission system operator tenant in Germany where they came out with a large number of HVDC connection, 12 in one shot, and they went to markets. We got half of them, 13 billion contracts, 3 billion US dollar contract with that.

You can imagine with that in, in ahead of us, ahead of you to be delivered the next. Five to six years, there is an opportunity to go project by project, get lessons learned, standardize improve efficiency, and that’s what’s the opportunity we are in front of us and customer get it.

Of course, they’ll still like to specify. And that’s the second message we are giving. No, we talk about standardization. We should not think about having equipment out of the shelf. No, I don’t think we get there, and we should be dreaming of that. It’s more strategizing the requirements and then the manufacturers will put all their innovation, their creativity, to make those equipment as standard, as reputable as possible.

We had to start with the requirements. No, as you said, the transmission system operators, the utility companies, if they could standardize their requirements as much as possible, that will help the supply chain big time. Not only Hitachi energy, the whole supply chain.

Allen Hall: Yeah. If we wanna build the grid quickly, we need to have some level of standardization.

The number of varieties of transformers that exist in the world is in the thousands. The tens of thousands at the moment, which is a little crazy because we’re just moving power from A to B. We can have some standardization. I and Hitachi being a huge company worldwide, global company, country to country, that changes also.

So you’re getting to different types of requirements in different countries. If we’re going to go fast, we have to standardize at least a little bit and have maybe have a little more flexibility, which I think is afraid of what your point is. Come in with a spec sheet, but have a little bit of movement in it so we can deliver you the products faster.

Because the grid buildout is important right now, right? We say we need to

Alfredo Parres: go at speed and scale. That’s the name of the game, and that’s standardization. It’s innovation technology, but also innovation business models.

Laura Flemming: Standardization doesn’t mean, it is off the shelf and it’s, I am, 100% identical.

So much time is being used up because every time you start with a blank sheet and start, designing and engineering from the ground up, what if we could start at 70 or 80% and then, specify and and personalize that last 20. That saves saves so much time, but also removes the the the room for error redesign, et cetera, et cetera.

And as of, as Alfredo was saying, that’s really gonna speed us up

Joel Saxum: and I want to touch on that too, because of. Big part of what you guys do, and Alan had said this earlier, even if you don’t really realize it, Hitachi is touching your life somewhere, right When you flip the lights on at some point in time, Laura and Alfredo had something to do with that.

But what I wanna say is that with all of the innovation and the work that you guys are doing, and we’re talking about kind of economies of scale and standardization and getting things done more efficiently. What kind of impact do you think that Hitachi’s work has on the public perception of renewables?

Alfredo Parres: First of all, I want to say we like to be humbled also. We are a large corporation. We do a lot of things. We are a successful company, but we are only one part of the whole value chain. And it’s true that the big weight is carried by the investors or the ones who have to build the projects.

The trust the utility companies will have to build those lines. So our contribution to that is, is very much in providing the education, explaining what we do, explaining the benefits of the technologies, or sometimes also to make sure we don’t get misleaded in some wrong concepts, nor what could be the impact on people of high voltage transmission lines to say something, so we can tell things in a simple way.

We like to do it, but we are only what we are. No, we are a technology companies. And we have to support all of us, those who are taking the major risk to to define, to provide investments to to talk to to, to people, to talk to civil servants, to talk to local populations, to say what’s, what are the benefits of those technologies?

Laura Flemming: I think what Hitachi Energy is doing is, really showing also how all of the different pieces, come together. A lot of our technology and equipment, it’s usually a little bit hidden, right? The in terms of renewable energy, the attention goes to the the, the lovely shiny turbines and the things, and the things that we see.

But they are also usually the ones that attract, a lot of the negative attention. And I think by showing how renewable energy. Can be integrated into the grid successfully. How we make sure that where the turbines are turning, that we don’t throw any of that energy away. Because we’re now optimizing, we can be more flexible and actually we can provide energy security because, at the end of the day, this has been one of the big drivers.

Particularly so since we saw the impacts after, COVID and in Europe, particularly the the war in Ukraine, how easily, we can really be caught on the back foot in, in terms of our energy supply. So providing that energy security is absolutely critical because, let’s be honest, as we go on and on as a country and as a population, we’ll be needing more energy as we go forward.

So bringing the public along is super important. I don’t think as an industry we’re doing enough yet. But I’m really pleased that since the summer, IT energy is now actually one of the key five key requirements and action plans in the UK in terms of what the government is driving forward.

So having that specific focus. On energy, the same as education, the same as health is is a massive game changer. And I think what that oil will also do is make a lot more people interested to come and work in the energy industry going forward, which is exactly what we need.

Allen Hall: So what does the energy future look like with Hitachi?

What should we be looking for in the next year or two?

Laura Flemming: I think we’ll be building a lot of projects. I will be, think we’ll be supporting a lot of customers. And I also think you’ll be seeing a lot of innovation in terms of how we speed up, how we do things more quickly and flexibly. But also how the grid is actually going to look like, once we’re actually building up to the capacity that we need.

How is digitization really going to help us, accurately create the flows through the electricity system? And making sure that at any given time, the lights will stay on.

Allen Hall: Lauren Alfredo, this has been a terrific discussion. I’ve learned a tremendous amount. I think the world needs to know more about Hitachi energy and what you’re doing to make the grid more reliable.

I. And larger. And Laura, how do people get ahold of Hitachi Energy? How do they find out more about the great things that Hitachi is doing?

Laura Flemming: Thank you very much. It was indeed a very interesting conversation. So thank you for inviting us. And for anyone who would like to find out more about Hitachi Energy please follow us.

Via the usual channels or find us on Hitachi energy.com.

Allen Hall: Laura and Alfredo, thank you so much for being on the podcast. Really enjoy speaking with you today.

Laura Flemming: Thank you. Thank you.

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Renewable Energy

The Trump Delusion

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As shown here, there are (formerly credible) people who are telling us that Trump is restoring Americans’ trust in government.

Do they truly believe this?

The Trump Delusion

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Renewable Energy

When Truth No Longer Matters

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One of the casualties of the post-truth era is that the statements of our “leaders” no longer are required to have any basis in fact.  What Jim Jordan says here is a fine example.

When he says “better” here, is he referring to runaway inflation?  Trump’s purposeless and illegal war with no end in sight?  His blatant corruption and criminality? His having, quite successfully, divided the American people into groups that hate each other?  The enrichment of billionaires at the expense of the working class?  The carefully engineered collapse of the environment so as to favor his donors in fossil fuels?  The demise of the U.S. educational system?

Please be clear.

When Truth No Longer Matters

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Renewable Energy

CNC Onsite Cuts Repair Costs With Uptower Machining

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Weather Guard Lightning Tech

CNC Onsite Cuts Repair Costs With Uptower Machining

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

Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on 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!

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

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

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

Søren Kellenberger: I am, yes.

Allen Hall 2025: So congratulations on that.

Søren Kellenberger: Thank you very much.

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

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

Søren Kellenberger: Yeah.

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

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

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

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

Søren Kellenberger: Uh,

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

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

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

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

Yeah

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

Søren Kellenberger: True. Yeah, yeah.

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

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

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

Allen Hall 2025: Okay.

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

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

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

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

So we do that in a week. Um-

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

Søren Kellenberger: Yeah.

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

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

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

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

Allen Hall 2025: get it done …

Søren Kellenberger: get it done. Yeah.

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

Søren Kellenberger: Yeah.

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

Søren Kellenberger: Yep.

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

Søren Kellenberger: Yeah.

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

Søren Kellenberger: Yeah.

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

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

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

Uh, yeah. Sure does.

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

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

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

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

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

Søren Kellenberger: Yeah.

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

Søren Kellenberger: Yeah.

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

It’s complicated. Exactly.

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

Allen Hall 2025: so- You take on those challenges

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

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

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

Allen Hall 2025: Right.

Søren Kellenberger: Uh-

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

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

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

Søren Kellenberger: Yes.

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

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

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

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

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

That,

Søren Kellenberger: that

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

Søren Kellenberger: Yeah, yeah.

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

That’s wonderful.

Søren Kellenberger: Yeah.

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

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

Allen Hall 2025: Yeah …

Søren Kellenberger: of that specific nacelle.

Allen Hall 2025: Okay.

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

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

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

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

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

Søren Kellenberger: Yeah.

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

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

Søren Kellenberger: Yeah.

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

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

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

Allen Hall 2025: Yeah.

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

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

Allen Hall 2025: Yes.

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

Allen Hall 2025: Wow.

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

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

Allen Hall 2025: Wow …

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

Allen Hall 2025: That’s large scale.

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

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

Allen Hall 2025: That’s huge …

Søren Kellenberger: really nice.

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

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

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

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

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

Søren Kellenberger: Yeah.

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

you can bring them back to life.

Søren Kellenberger: Yeah.

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

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

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

Allen Hall 2025: Yeah

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

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

Allen Hall 2025: Sure.

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

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

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

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

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

Allen Hall 2025: Right. Yeah.

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

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

Allen Hall 2025: Yeah.

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

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

Søren Kellenberger: [00:19:00] Yeah.

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

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

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

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

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

Søren Kellenberger: Yeah …

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

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

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

CNC Onsite Cuts Repair Costs With Uptower Machining

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