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Improving Blade Quality: Challenges and Opportunities with Mohammed Fajar
Rosemary had a great discussion with blade expert Mohammed Fajar about blade defects, the blade design and certification process, and how optimization and automation could improve blade quality. Mohammed provides perspective on recent issues with turbine OEMs like Siemens Gamesa, and expresses optimism about wind power’s future, particularly offshore! With both of their extensive blade knowledge, they explore how human factors in blade manufacturing lead to inconsistencies and why the industry struggles to implement more automation.
Sign up now for Uptime Tech News, our weekly email update on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on Facebook, YouTube, Twitter, LinkedIn and visit Weather Guard on the web. And subscribe to Rosemary Barnes’ YouTube channel here. Have a question we can answer on the show? Email us!
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Rosemary: Hello and welcome to a special episode of the Uptime Wind Energy Podcast. I’m Rosie Barnes and today I’m joined by Mohamed Fajar, founder and blade consultant at Apex Wind. We used to be colleagues actually at LM Wind Power when Mohamed was a senior structural design engineer who took five blade designs through the certification process.
So wind turbine blade defects are very topical at the moment with what’s in the news with Siemens Gamesa and also TPI, we’ve talked a lot about that on the podcast. And I thought that Mohammed would be the perfect person to have on to tell us about how the blade design and certification process works, or maybe more accurately how it should work to ensure that blade defects aren’t a problem.
They’re not supposed to be. So thanks heaps for coming on, Mohammed.
Mohammed: Thank you for inviting me.
Rosemary: So I just wanted to start out. Can you tell us a little bit about your background and what you’re doing now at Apex?
Mohammed: I graduated in 2014 as a master in engineering in France about composite structures and materials.
And since then I joined LM Wind Power in Denmark and my journey with blades started. So I started as a structural design engineer. Yeah. As you say, designing blades, for various OEMs, uh, taking them from the conceptual design to the Yeah. Manufacturing and handover to, to the factories. Also worked at yeah, a company called R& D test systems also in Denmark doing test systems for wind.
And then another three and a half years in Vestas in the innovation department. I was working a little bit as the blade owner in the department tech lead in, in all blade related projects. One of them, it’s the, yeah, cable stay drawtor where I also worked on it from the start to almost the end of it.
And then since July 23 I went on my own. I started Apex Wind, as you mentioned, and the goal is, yeah, to have this. It’s a consultancy company, a hundred percent focused on blades. Uh, helping developers, OEMs and startups yeah, to have a blade expert on the side when they need it.
Rosemary: Yeah. It’s good timing to pick a company like that, founding a company like that, because it’s definitely such a need for blade consultants these days, but with yeah, all of the issues that we’re seeing.
Mohammed: Yeah. One of the things that really motivated me to get in, because when it was, for example, on the OEM side, sometimes I feel that there was a struggle finding someone who knows about blades and can help with blades.
Often you end up, even if you want some CAD resources, you end up hiring someone who works with steel or something, and then almost have to teach him how to work with composites. And there was never this full package for people who knows about the whole value chain of blades to know about the design and then the manufacturing, the certification, the testing.
Often I compare it to some other components of let’s just say the nacelle in in, in big companies. You will have the same number of engineers working on the nacelle as working on the blades. And in the place we’ll have all these specialists on lightning on, on foams, on glass and then on liquids and then paint. And that’s why actually sometimes it gets very hard to get that person who can cover all these areas at once.
But yeah, and then the demand is big, but also the issues and the struggles, often they make a lot of noise in the media, but also the cost a lot of money to both, yeah, OEMs, developers and insurances and insurers and so on. And yeah, actually had this. sentence or this mission, when I started, just try to make blades a little bit more reliable again. Because with all I thought, I don’t think there’s a specific person or company to blame, but there is this pressure on costs.
There is these quality issues that keeps coming and then The companies that are trying to fix it, they’re spending money on it, they start maybe spending a little bit of on innovation on new products and so on. And then you just end up just fixing what you have. And sometimes it gets too big that you stop selling some platforms or turbines like what’s happening to Siemens Gamesa at the moment onshore.
Yeah, if I can help a little bit with that, I will be very happy.
Rosemary: Yeah, it’s a timely service that you’re offering. And I think that a lot of manufacturers would be happy to have that resource available. I think maybe it’d be good to start out by giving some background for people that aren’t totally familiar with, what are the issues with blade defects these days?
Can you maybe help just summarize? So I’m talking about Siemens Gamaces their issues with, I think they’ve had some wrinkles and some issues with their bearings as well. Maybe not so specifically blade related. Last time that I checked in, they were up to quite a few billions of dollars in expected cost to remedy that.
And then there’s a little bit from TPI as well, not to the same extent. Is that the issue as you said, or do you have anything to add about what the state of wind turbine blades are these days?
Mohammed: Actually, yeah, there is actually Yeah, a big group of blade defects that happens and some of them happen just during the transport and sometimes they’re just aesthetic.
Majority of them, or like at least the ones that have worse consequences, is the ones that happens often in the factory or even worse during the design. But actually what happens during the design, I have just a feeling that it’s maybe OEMs, they will have a really hard time to admit it. So often outcome of the root cause will come as manufacturing and we all can do, cannot do much except trusting that.
But yeah, in the factories, actually, there is a lot of NDT, non destructive testing that you can do in UT scanning and so on. And you can, again, you find the defect that you find, and then the ones that you don’t find, that’s the one that goes in the turbine.
And that’s the ones that we hear about them a few years later. And yeah, you mentioned wrinkles, wrinkle, it’s actually it’s main and one of very dangerous defects that happens. Yeah, as you said, Siemens Gamers, they also mentioned they had one of these defects in the platforms. They have stopped and they’re actually the physics are easy. Like you have laminate, if half of it is wrinkled, then basically you lose half of the strength. And then once the part that is not wrinkled cracks, then the part that is wrinkled it gets straight and then cracks again. Now actually a lot of days they have these protrusions, carbon protrusions where wrinkles, it’s less of an issue because you can actually control it before placing it on your blade.
But at least let’s say in the root part where you cannot use these protrusions wrinkles yeah, are very present. And sometimes you cannot even find them with this UT methods because if there is just some foam in between the glass, then you cannot get the signal anymore. And let’s say they don’t come from your design and then you have, you design a blade and then mark and then you fix.
You manufacture it in four different locations in Europe and South America and China, you can get three blades that are almost completely different because at one point your design documentation and QMS systems and quality and so on, it has some limitations. And then it ends up at the hands of the people, placing those plies and applying that vacuum and gluing your blade together.
And that’s actually one of the main struggle that people try or OEMs trying to fix, but you do your best, you train people and so on. But there is, yeah, there’s a big turnover in in, in those factories and you end up sadly with, in some cases and actually the CEO of Siemens Games mentioned it in his call last week that he mentioned the Mexico factory. Then it means that Okay, sometimes just one factory can have a lot of defects that some other factories doesn’t have.
And even if your design and all your processes are exactly the same, right? And this also proves or shows how complex is the whole situation because that blade the if it’s designed in, I don’t know, in, in the US or in China, you, it is the same certificate and it’s certified by the same certification body and everything is checked in the same way, but at the end you will manufacture it in two places.
You might get two places that are pretty different actually.
Rosemary: That’s a really good little teaser for the issue that I want to get to at the end. And it raises the whole point of what I wanted to talk to you about, which is how are we supposed to make sure that doesn’t happen. That you just have blades of random quality making it onto wind turbines, which I think is every, wind farm owners biggest nightmare is that, they’ve bought these very expensive wind turbines.
How do they know that they’re not going to the blades aren’t just going to snap off. So I was hoping that you could walk us through step by step, how the process works, so starting off with yeah, how do you even design a blade, a wind turbine blade, and then what is the certification, the manufacturing, the quality checks, how does that work to yeah, supposedly ensure the high quality of all these blades.
And then maybe after you’ve talked about all that, we can go through how it goes wrong and why?
Mohammed: First you will decide that, okay, there is a specific type of turbine that you’re interested in making. Then actually you will have your loads team and aero team and also a little bit the structural team working on defining just the big parameters of this turbine, the exact diameter, the core distribution, the twist, uh, and so on.
And then the outcome of that first step will be an outer geometry of your blade that still might be changed later on during the design phase. But as they say, the big dimensions are fixed and then a good idea about your loads the fatigue loads and then the static loads in the different direction that you will need to design the blade for.
Once you have that, then you will have the structural design engineers starting working. And basically what they will do, they have different tools and then they will start placing almost layer per layer. You can have like thousands of layers sometimes in some blades. Placing that, running your analysis with the loads and then checking the main first failure modes or design drivers, let’s say the strain distribution, the buckling in some panels on the blade. And then iterating, a lot of iterations, adding a little bit of material here, removing from there, checking your load models, making sure that the loads don’t go up too much. Checking some constraints you might have, maybe some tip to tower clearance, maybe some specific ion frequencies that you want to avoid.
And at the end of this first step, then you will have a first kind of conceptual design with the right geometry, the right trailing edge thickness, the right blade circle diameter, root circle diameter. Once you get all that, then actually you go one step further into your design and you start doing some finite elements analysis, which is a little bit some more details analysis on like very small details on your design.
So once you get all that done, then you start involving the certification actually, which is a third party that often the customers will ask for them to certify your product. And then you start sharing with them some of your models. And while they are doing that, you will actually start preparing your full scale testing, because every blade needs to go through a full scale test. And in that phase, you also have some people from the third party certifying your blades coming and doing some audits. Yeah, you manufacture the blade, you ship it for testing. You do full scale tests which take actually many months, the fatigue testing, it’s many millions of cycles.
And then you have to do a static or extreme test before and after that one. And then depending on how much risk you want to take, you can launch the full the serial production before the end of the testing, because often you cannot afford waiting six months or a year for the testing to be completed.
Rosemary: I’m assuming that the team on the certification company is not as big as the team at the manufacturer. So how can they possibly check all of that information in enough detail to be sure that you’ve done it right? Or are they then relying on the fact that you’ve made a test blade didn’t break that means everything’s okay. I just how do they get enough certainty from it?
Mohammed: They check what they can do. They cant rebuild the models, maybe some try to build some the, that finite element modeling and run it. But no matter what they do, they will have to put a lot of trust in what you have done. As I said, there’s many people working on that blade design sometimes can easily go up to 50 or a hundred. And then when you look at the certification parts, two or three people working, for example, on that structural design part, or even less.
They will not certify that this blade is perfect, but it was again, certify that you follow the steps that you have to, and you follow this IEC standard 61400 for lightning or for structural or for testing. And so the system has large limitation and that’s also why, for example, many developers, they have their own qualification system.
Of course. The certification you need to certify, but themselves, they will try to look at some design parameters. They have, they will look again through the, I don’t know, the power generation data. They will go and do some audits in the factories. And even after doing this you catch what you catch and then what you don’t know, you probably never know it.
And some defects, they appear during the lifetime and some they don’t even appear actually because they’re not that problematic. And we learned to live with that. I would say the majority don’t have any problems, but if you are a developer, you don’t want to get those ones that fail so you have to do all these checks.
Rosemary: Okay, so I’ve got a follow up question. I know that you mentioned that you make usually one test blade. It’s one of the first blades that you have made. There’s a high chance that it you know, has a lot of the issues in it that you haven’t figured out yet. I’ve spent a lot of time in wind turbine blade factories, and I know that every blade that comes off the end of a production line is not exactly the same. There’s different defects in every blade and they’re always doing repairs.
So how can you hope to capture the whole range of problems that you might have if you just test a single blade? How does the certification process deal with that or the design and certification process, is a better question to ask.
Mohammed: If you do some lab tests of small composite parts, you really need to test a big population to really be certain of integrity of that part.
In blades it’s a bit different because we talk about blades of 100 meters, it’s a high cost, and it’s also every blade takes many months, so you cannot afford doing seven tests, it will ruin the whole business. One way of dealing with it it’s basically with partial coefficients. So in, in the certification standards, basically because of the, this variation in manufacturing, you will add a factor of, I don’t know, just saying random numbers of 1. 1. Because of this variations in fusion or in, in the uncertainties about your load model and so on. You will keep adding these small partial coefficients and then you end up sometimes depending on your process, you end up with, I don’t know, partial coefficient of, let’s say two.
And that’s already actually means that your blade, it’s actually two times stronger than the nominal one, but it’s because there’s a lot of variations again. And then there is variations in the loads, there is variations in the structure and you don’t want these variations to start overlapping that you will have in some cases a blade that is weak enough because of all these deviations.
And then a load model that is not conservative enough that you will end up with these blades failing. And then you also do overtest actually those blades to some level. In static you will test them 10 percent more and then in fatigue depending on your number of cycles and your strain, you might test it up to 33 percent more.
Rosemary: No matter what your best efforts are sometimes you are going to get, defects that occur occasionally in serial production that didn’t happen in the test blade. Or I guess you do get the occasional unlucky blade where just every single possible parameter you’re at your worst case scenario, and they will all line up like holes in Swiss cheese.
So then you see issues like what we’re seeing in the news today with Siemens Gamesa, TPI, the main ones that I’ve heard of, which you’ve already talked about today. Do you feel like there are more blade defects than normal at the moment?
If you do think that there’s more than the normal amount of defects, what’s your thoughts on why that is and what that means for the future of wind?
Mohammed: Actually, I think there’s much less defects than before.
Because also, actually, there was a lot of progress yeah, but when just the engineering part, there was some, actually now more, much more calculation is done than before. And also in the manufacturing with all these new methods of being lean and then the quality management system and so on. I think they are getting less, but actually the ones that still makes it to the blades, those defects, they have a bigger impact now because we’ll, we became better, I think, as making blades at making less defects, but we also squeezed all the kind of the juice where we really pushing the limits and then going really designing to the limits and so on.
So maybe before you would have 10 small defects because of your manufacturing, but you had a little bit extra capacity in your structure that did want to be a problem. But now maybe let’s say you have just one out of these 10, but because of The very optimized blades, I would say one wrinkle that you don’t catch might be a big problem.
And that’s why having control over your manufacturing, it’s actually, it’s so important if you want to keep innovating, bringing new materials and then having this detailed analysis that you can use. You cannot benefit from that if you’re manufacturing is not like really almost perfect.
And that’s the problem I think blades have. I think almost everybody will agree with me. It’s the manufacturing that is still very like labor intensive. And then when it’s humans making that, it depends on where they are, if they had a bad night, if they have paid well, if they are stressed and all these factors, actually. You can have the best design you want.
You can reduce the number of defects, but yeah, the human factor is so important and then how can that be fixed? Often it will require money. And then again, the business case start suffering. Because you can say that why aren’t we automating all this process some simple ones like placing glue or placing some layers?
But, I worked in some many actually projects trying to add automation into factories. Very often you end up having more expensive blades that nobody will want to buy. And then you end up somehow, I don’t know if it’s intentionally or not admitting to like to have this quality issues than to invest in automation and then remove these quality issues.
Because at the end, even if those blades fails, it’s still actually better business case than a fully automated factory.
Rosemary: Okay. That’s a, yeah, that’s a really good perspective. And maybe we’ll have you back on another time to talk about wind turbine blade manufacturing, because I think that’s a whole huge topic that people don’t necessarily understand that well.
Yeah, particularly how manual the process is and all the quirks of composite materials. Thanks so much for coming on. And can I just ask a parting question? What do you think the future for wind is? Are we going to, make it out of this current crisis? Will we see bankruptcies? Do you think it’s overblown?
What’s your little snapshot of where you think we’re going?
Mohammed: I think there is still a future for wind, also mainly for offshore. Actually, it looks very promising. LCOE, it’s just decreasing and decreasing. And maybe that’s also why we are seeing all these problems. But I think it will stabilize at one point. I hope that will happen.
And then we have this healthy kind of industry where nobody’s taking kind of the losses. If it’s a supplier, OEM, or a developer, or the end customer. I think actually, I’m very positive, I would say. And then I think the solution in all that will often be, yeah, technology and innovation. I know also trying to keep the amount of platforms and product existing in the market very limited so that OEMs can benefit from it.
But only the market can regulate itself. And only the market will regulate the size of turbines. Only the market will regulate the end price. And it has to converse to a good balance point.
Rosemary: Thanks a lot for listening to this episode of the Uptime Wind Energy podcast. Don’t forget to like and subscribe if you’re watching on YouTube. Or if you are listening on a podcast, please leave us a review. It makes a big difference to other people finding the podcast. Yeah, thanks again and we’ll see you in the next episode.
Improving Blade Quality: Challenges and Opportunities with Mohammed Fajar
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Rosemary previews Pardalote’s new hands-on blade repair course. EverWind’s Ocean Lake, Canada’s largest wind project, will feed a green hydrogen and ammonia plant in Nova Scotia rather than the grid. Plus BP’s exit from an offshore project in Japan, and the wake-effect lawsuit pitting SSE, Equinor, and Vårgrønn against RWE’s Dogger Bank South.
Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTube, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!
The Uptime Wind Energy podcast, brought to you by StrikeTape. Protecting thousands of wind turbines from lightning damage worldwide. Visit striketape.com. And now your hosts
Allen Hall 2025: Welcome to the Uptime Wind Energy podcast. I’m your host, Allen Hall. I’m here with Matthew Stead, Yolanda Padron, and Rosemary Barnes is back this week.
Rosemary, you’ve been to a number of training courses over the last couple of weeks. The first off was GWO. What was your experience at GWO training?
Rosemary1: It was the fourth or maybe even fifth time that I’ve done it. Um, I did it a few times in Denmark and then, uh, this is the second time doing it in Australia. also, this was my first time doing first aid in Australia. Last time they did GWO here, but my first aid was still valid from Europe, so I, I didn’t redo it. And it’s like so much about [00:01:00] snakes and spiders and jellyfish But a good, good rule of thumb, not 100% accurate, but good rule of thumb, if it is something from the ocean that stung you, then you put something warm on it, and if it’s something from the land that stung or bit you, then something cold on it,
Allen Hall 2025: well, how often do you usually take GWO training?
Rosemary1: You gotta do it every two years to be valid. I don’t do it every two years because, um, if you do it every two years, like within two years, then you can do the refresher course. So that’s three days instead of four However, um, because I don’t climb constantly, like often it will be six months or more in between climbs, I’ll just do it before I know that I’ve got a climb.
all the other people except for one were technicians who, you know, have been working for a while.
So they’re also doing the full course, not the refresher. So they get a little bit more practice than I do. But, um, it’s just not often enough. Y-you know, like every time I go it’s like I, I really feel the need to have the refresher, um, because I’m just not fully on top of it. ‘Cause it’s [00:02:00] not just that you need to know what to do. You need to be able to… Like if you need to use it, you’re gonna be freaking out, you know?
This is the worst thing that’s probably ever happened in your life, and now you’ve gotta remember all your training. It’s like you want it to be actually second nature to some extent. So yeah, first day is manual handling, which is v- you know, very– That one’s very easy and I would be happy to never do that again.
Like I will always remember that. Um, then you got fire, um, fire safety awareness, and that one’s just fun ’cause you just get to, um, light fires and put stuff out then first aid, which I definitely always want a refresher on.
The CPR dummies at this place, they had lights, um, and it lit up green if you were doing it right, and I haven’t used a dummy that was so advanced before, so that was quite good. I realized I wasn’t pressing hard enough. and then yeah, last two days is working at heights training, which is the most intense ’cause you got your harness on all day and, um, you know, climbing up and down and rescuing people.
this was Rite Training in Goulburn, and, um, the [00:03:00] instructor’s name was Claire. highly recommend doing that one.
Allen Hall 2025: Is that a general requirement in Australia that you have GWO before you can climb?
Rosemary1: Like, yeah, they will sometimes, um, let you climb if you are babysat by people. I would not recommend other engineers, like if you’ve never climbed a wind turbine before, like I would really not recommend that you just go up with a team and haven’t done the training because you do need to be able to use a ladder safely and, um, you can, y- you can easily, like even inside the nacelle, you could easily hurt yourself really badly if you’re used to working in an office, uh, you’re upping your danger level by, you know, like many, many, many times by going up a turbine and it’s just something that you gotta take seriously.
Allen Hall 2025: How busy are the courses in Australia? Are a lot of technicians trying to get in and get trained?
Rosemary1: No, it’s people that have a job that are getting trained. But there were heaps of techs in this course. There were maybe eight or so, which is also part of the reason why it took a really long time.
Allen Hall 2025: So [00:04:00] this week, as we record, y- you’re presenting a blade repair course for engineers and technicians. a completely new area that you’re, uh, going into in terms of offering advice and expertise that it’s really hard to find on the planet. It’s probably a, a, a busy or, or requested course, I would imagine, in Australia, where you just don’t have access to a lot of the manufacturers.
Rosemary2: it’s a, it’s a course for just for engineers or technical type people, um, but including hands-on stuff. So the way that I I forced this to come into being was just the last five years. I, um, you know, I started working a lot on wind turbine blade repairs and, um, people would ask me, you know, “Have these repairs been done right?”
And the thing is that the only repairs that I had anything to do with when I was working at LM were weirdo ones, right? [00:05:00] Where the normal, like a technician couldn’t, couldn’t handle it. It was outside of, um, yeah, their, their standard, uh, kind of repairs that they can do for whatever reason. and now in the work that we do at Part Load, it’s primarily normal repairs, and I just didn’t know exactly what technicians know. You know, how do they, how do they know whether they can repair it or not? What do they know before they go up there?
When are they calling the engineer? Um, all that sort of stuff, like the normal stuff. eventually it became less about me learning, ’cause like I said, I kind of picked up most of it. Um, but now I’ve got staff that I’m training up to be, uh, you know, composites engineers and to work with these kinds of issues. There’s a lot of repetitive tasks involved in what we do when we, like, assess the condition of a wind farm.
A lot of what we do is look main- manually looking through photos and thing- if things are classified right or not. I [00:06:00] Found this guy from Direct Wind Services, Jurij Eska. He’s a blade engineer. He’s worked in Europe and then come back to Australia, so a little bit like me. And, um, I just worked with him on a few projects and I’m like, “Oh, okay. Well, this guy, uh, he really gets it.” And I asked him, “How do you, how do you train your technicians?
What course do they do? Maybe I can do that course.” And he said, “Oh, we train them ourselves.” And so then I asked him to put this course together. So where we started off the course yesterday, that was, um, uh, an indoor session where I was talking through how are blades designed, uh, certified, tested, manufactured, um, what kinds of manufacturing defects can you see and what do they do about them in the factory?
‘Cause you know that they’re doing a lot of repairs in the factory already before you ever see a, a brand new blade. and then the next three days we’re going to be working on, um, yeah, grinding and [00:07:00] infusions and a bit of a, a bit of theory about, um, composite repairs.
Allen Hall 2025: What do you feel like are those key skill sets that engineers should know how to do, maybe not as well as a, a professional technician that does it a lot, but at least at a beginner’s level should be able to complete them before they start repairing blades on their own and giving advice about how to repair blades?
What, what are those key items?
Rosemary2: part of it is that I want them to be able to understand what is a bad damage and what’s not a bad damage cause you look a lot at images from the outside, but it’s really about what’s on the inside and how deep it goes is the real thing.
So, um, it’ll be about learning, you know, developing some judgment about, um, how bad it can be and how bad it can look on the outside. We’re not gonna be looking at so many real damages ’cause like obviously we’re just dealing with pieces that are in the, um, in the, uh, workshop and Yuri has [00:08:00] made some samples for us, um, purposely made them badly so that we’ve got some, you know, damage to find.
Allen Hall 2025: Are you addressing carbon fiber at all?
Rosemary2: Uh, I actually haven’t asked about that. I don’t think so. Carbon fiber is, um, is a real pain to work with because it’s conductive. Like, even grinding it makes a bit of a hazardous work environment. We did talk a little bit about the different materials yesterday and, um, about pultrusions. And actually, it turns out Yuri used to work somewhere where they, uh, manufactured pultrusions, and I had always, I was always under the impression that a pultrusion is, you know, like, perfectly s- perfectly straight.
That’s the point. And he’s like, “No way.” No way. There’s waviness in the pultrusions
Allen Hall 2025: And on March 3rd through 5th at WOMA 2027, Rosie, you’re gonna give part of this course as part of WOMA, right?
Rosemary2: Little, little mini course. We’ll have to decide what, what makes sense to include, ’cause it was… Yeah, I went through really a, a fair [00:09:00]bit about blades yesterday, you know, like why they are shaped the way that they are. So we had to talk about aerodynamics and, um, why they’re made of composite. So we had to talk about, you know, like composite materials, like how, how they, how they work So I don’t know if, uh, people wanna write in comments that m- we should, we should do some sort of, um, poll beforehand to see what are the topics that are most interesting to people, ’cause I think we’ll have a half day, right? So we’ll need to be, we’ll need to be focused.
Allen Hall 2025: the description of repairs and what repairs should look like could be tremendously valuable. Everybody who has seen a repair always wonders, “Was that repair done right?” And s- and if you can have some general tools to know, like, “Uh, maybe there’s something not quite right here,” or, “That looks like a solid repair,” that would be a tremendous help to the industry, p- particularly for asset managers
Rosemary2: Yeah. And you know what I think is even more useful than being able to pick out when it’s wrong is to be able to know when it’s right. You can– Y-you know, like it is so– [00:10:00] It’s such a relief. Like it takes such a mental load off you when you’re just like, “Yeah, that’s all, that’s all good. That’s normal. Okay, I know that that– I knew that that would happen, so this is not a surprise.”
‘ know, once you know you can make that judgment, you can do it very quickly and focus your attention where it should be, so you don’t need to stress for an hour over every repair. You’re just like, “Yeah. Good, good, good, good, good.” And then, “Mm, please explain why you have chosen to not, not repair this, but just put a Band-Aid over it.”
that’s the goal of this training is to get everybody, y-you know, technical people, not people who wanna ever be a blade repair technician. They’ve got their own training that covers what they need to know. But this one is just, yeah, getting people like asset managers or my employees to learn what they need to know about composites, given that they have already got a strong engineering education.
So, um, you know, they know a lot of the stuff, but just need to know the composite-specific stuff and wind turbine blade-specific stuff
I will run this course again, by the [00:11:00] way, ’cause there was a lot of people who wanted to do it I couldn’t fit in. So it’ll happen at least once. I’ll keep on running it until everybody that wants to do it has, has done it. But, um, yeah, feel free
to get in touch
Allen Hall 2025: So if you wanna attend Rosie’s short blade course at WOMA 2027, just visit woma2027.com and register today
Allen Hall 2025: [00:12:00] Well, over in Canada, they just approved a, really a wind farm big enough to power a small city, and almost none of the electricity is going to the grid, which is a very interesting aspect to some of the things that are happening in Canada at the minute.
So up in Nova Scotia, uh, they’ve conditionally approved the Ocean Lake Wind Project. This’d be the largest wind farm in the province’s history. Up to 158 turbines will rise, uh, generating as much as 1.2 gigawatts of power. But this power is not headed to households in Canada. Nearly all of it will be feeding Everwind Fuels’ green hydrogen and ammonia plant at Point Tupper, where clean electrons will become a fuel that can be shipped across the ocean to Europe. And Matthew, there’s been a lot of [00:13:00] projects like this in Europe that have stopped more recently, particularly in northern Europe and up in Scandinavia, uh, on the hydrogen side. Or at least they’ve slowed them down. Canada seems to be going into that breach maybe to fill that void. And is there a marketplace for this to occur up in Canada?
Matthew Stead: Yeah, I think it’s very interesting. Um, you know, like you say, a number of canceled projects, and in Australia there’s been numerous canceled projects. So I like, um, the analogy or use of the term hopium rather than hydrogen, um, where, um, everyone’s hoping hydrogen will be the answer. Um, although, you know, what I, what I’ve read and understood is that, um, you know, the commercials just don’t really stack up and, um, yeah. So in terms of South Australia anyway, um, there was some major, um, hydrogen, uh, development planned with, um, you know, it, it never stacked up. So, you know, it sounds like a great [00:14:00] idea, um, but I’m not sure that the commercials will ever stack up unless you’ve got that guaranteed offtake for the, for the ammonium
Allen Hall 2025: Yolanda, what kind of uphill battle is this to get this wind farm up and running knowing that it’s one customer and that commercial market is a little shaky at the minute?
Yolanda Padron: what we saw, they have a lot of ca- caveats, right? So they’ve, they need to secure the customers before they start building and before they do anything, um, behind the meter. But it’s, I mean, it’s, it’s a pretty big wind farm, and it’s pretty far up north. But I mean, we, we talked to someone in, in northern US today who was having icing issues.
So I mean, of course we know Canada is no, no stranger to that, if they do make it work, I think it’d be really, really exciting to, to have sort of one technology power another, um, instead of just what we’ve been hearing a lot of the potential data centers and, and just wind po- [00:15:00] powering data centers.
Matthew Stead: Why not data centers? You know, seriously, like you said, Yolanda. why not go something that does have commercial demand?
Yolanda Padron: we’ve talked a lot about the potential of da- data centers, right? And we’ve talked a lot about people wanting to do them. Um, but there’s also a lot of talk of potentially doing data centers up in space and a lot of talk of maybe what if we do it offshore or, you know. And so I think there’s a lot of what ifs with data centers.
Of course, there’s a lot of what if with this, but just from a technology standpoint, I think this is really intriguing to have something that’s, that’s a little bit even more out there than what we’ve heard so far
Allen Hall 2025: Is it a build it and they will come type of s- situation here that hydrogen and ammonia may be the, the first offtake, but realistically, if that doesn’t work out, they can still connect to the grid and feed Canada, feed the Northeast of the United States or something else
Matthew Stead: Also, um, like Japan has [00:16:00] also expressed strong demand for, um, ammonia, and so, you know, they- they’re on the East Coast, aren’t they? So, you know, shipping it from East Coast to Japan is not gonna be so, so easy. I stick by what I said before. It’s hopium. it’s not a plan
Allen Hall 2025: I just saw an article today talking about Airbus continuing on with a hydrogen aircraft, and I think they were gonna work with a Japanese firm to work on that together. Six months ago I thought that died, but maybe it’s still in the offering. Maybe there’s an offtake for hydrogen. B- besides the, you know, replacement for some of the, uh, more unpleasant gases that are used in steel production and in some other industry things, maybe part of this is airplane fuel.
Which ammonia is one of those offerings also, right? The, there’s been a number of efforts to turn ammonia fuel into essentially jet fuel. They configure the engines to burn ammonia, which is a possibility. It does seem remote though, [00:17:00] honestly. There doesn’t seem to be a huge pull for hydrogen, and there’s not a, a major market for ammonia at at least at the moment.
So I don’t know. It, it’s… When you’re talking about gigawatts of capacity you’re gonna build, you, you hopefully have an offtake
for it
Yolanda Padron: if they designed it for it being not connected to the grid, right, it just is kind of like a behind the meter thing, and then could they later retrofit it into there? Like, how would all that permitting and everything
Allen Hall 2025: I–
well, that’s a great question. I– There are a number of, uh, connections between the United States and Canada at the moment. guess is that when they place this wind farm, they have that alternate route lined up, just like any wind farm in here in the States, that you’ll find them real close to high-voltage transmission lines.
Generally, those are the easy ones because transmission lines cost money and take time for permitting. I’m not sure Canada has those kind of restrictions, right? But Nova Scotia is not the easiest place in the world to do heavy construction work, just the [00:18:00] nature of Nova Scotia. It will be fascinating to see how they progress with this, but it’s something to keep an eye on because a lot of other projects like this have slowed down
Matthew Stead: Do you remember when some of the OEMs were talking about, um, putting electrolyzers on their offshore wind turbines? So the, the theory, the theory was you’ve got offshore wind turbine, you don’t connect it to the grid standalone, um, and you generate hydrogen or, uh, possibly ammonia on the actual wind turbine.
And then every now and then you just decant it, you know, drive up with a boat, you know, plug in the hose, and then suck out the hydrogen or ammonia. So, um, yeah, once again, all of those have gone quiet, haven’t
they?
Allen Hall 2025: speaking of Japan, a global oil giant is walking away from the Japanese offshore wind project, uh, but the project’s not dying. BP has told its Japanese partners it intends to withdraw from a wind farm planned off Yamagata Prefecture, uh, apparently worried about [00:19:00] profitability. The 450-megawatt project sits, uh, just off the coast, and it is led by trading house Marubeni, which says it will press ahead without BP.
Kansai Electric and Tokyo Gas remain on board also. So BP’s exit follows really a, a brutal year for Japan, where Mitsubishi has, and some others, have pulled out of, uh, at least three projects so far, uh, over rising construction costs, and I think a lot of that’s tied to inflation. Uh, the ambition’s still there for, uh, for a number of companies, but it’s just getting harder and harder to do projects in Japan.
Is this just the nature of the economy in Japan at the moment, or is this more about Japanese policy on the offtake,
Matthew Stead: I, I’m not really deep into the details but, you know, it just appears to me like a blip. I mean, there, I think there’s a lot of commitment in Japan to, you know, carry [00:20:00] out their offshore developments and I, I think this is probably more just a blip, um, and a little, you know, internal corporate, you know, argument rather than a sustained issue on offtake agreements and so forth
Allen Hall 2025: Well, Yolanda, how hard is it to keep partners on a wind development in general? Are there a lot of moving pieces there until the turbines hit the water or hit the
earth?
there’s
Yolanda Padron: I think a lot of moving pieces, but not, uh, I haven’t seen a lot of changes once it’s been publicly announced and everything’s, you know, everything’s been signed and everything. Um, I do think this is really interesting. I know we’ve talked a lot about, about having, about the idea of like sometimes people think wind’s really expensive, and the way that we’re gonna make wind work is just making it cheaper for everybody and just optimizing it as much as possible, um, and, and just being, having the turbines be as resilient as possible, right?
And I think such a strong player just backing out maybe [00:21:00] will incentivize some of the people in Japan to sort of try to see how they can optimize it a little bit more. I’m really excited to see it. I don’t know. It’d be… I think it’d be a nice it
Allen Hall 2025: Isn’t the bonus to offshore wind the price stability? Although the price may be higher today than you may be happy to pay, the stability of that price is a huge leverage point when you compare it to things like oil and gas or natural gas, um, in particular, which are highly volatile, that for electricity, at least you have this fairly steady source at a fixed price that you can plan out 10 years, 20 years, 25 years, maybe even 30 years. And as batteries become more prevalent on the grid, that the math even gets better over the years. Isn’t that the bonus? And, and if [00:22:00] everybody can focus on the long-term effects to the economy is where all the action will be?
Matthew Stead: Yeah, I mean, when I first, um, started looking into wind, you know, 10 plus years ago, I, I won- wondered why. Why would you build offshore with all that expense? And then, you know, it became clear to me just around the, um, you know, the diversity, you know, the, the fact that you might get more wind at times that you don’t get onshore wind, and the fact that it’s more consistent.
Um, yeah, and, you know, so those… I- it’s really a trade-off, isn’t it? Between the capital costs and the, um, more reliable, more consistent, um, offshore wind. So I think, you know, I, I was convinced at the start, I thought it was crazy, but then obviously it’s, it’s a, it’s a… it makes sense
Yolanda Padron: Yeah, I agree. And I think, uh, depending on where you’re having your offshore wind farm, you run into things that you maybe haven’t run into before, right? I know onshore we run into a lot of things in the [00:23:00]US and Australia that we, you know, the, the turbines just maybe weren’t designed for, or there wasn’t a lot of research being done because it was being done in Europe and, and the conditions are really different.
Um, and just the same way, you know, the sea is different in different places. There’s different depths. There are diff- different things that you need to worry about. but yeah, I, I completely agree that there’s a lot more generation, um, offshore. It’s, it’s bigger turbines. Um, there can be bigger, larger costs. You know, if you need to do a blade replacement or something, it, it can get, again, really expensive really quickly. But, but it’s, it’s a trade-off for sure.
Allen Hall 2025: We’re gonna take a quick break, but when we come back, we wanna talk about a place where wind is being fought over versus projects slowing down
[00:24:00] over in the UK, there’s a big fight about offshore wind, and not just about where wind turbines will be planted, but more about how they will affect other wind turbines.
So RWE is defending the UK government’s approval of its three-gigawatt Dogger Bank South project, which won its consent order, uh, basically a month and a half ago. Uh, but the developers next door are taking that approval to court. Equinor, SSE, Vårgrön own the neighboring 3.6-gigawatt Dogger Bank wind farm, and they have filed for j-judicial review.
Their argument is technical, but the price tag is not. They say wake effects, where one wind farm steals the wind from another due to turbulence, could cut their output and cost them between €500 million and [00:25:00] €669 million over the life of their project. That’s a lot of money, Matthew. A half a million euros is not something to ignore.
It looks like this is headed to some judicial court or maybe arbitration. Wake effects, which are actually not that well understood from what I can tell at the moment, there’s a lot of discussion and argument about, uh, how real are they or, or what effect they can have on power output. Uh, there’s a lot of money at stake, and the location of some of these wind farms is pretty close to one
another
Matthew Stead: you know, we always, always talk about, you know, AEP loss and, you know, the, the challenge is actually measuring it. And, um, you know, I’ve heard different numbers, but, you know, plus or minus half a percent of AEP loss, um, appears to me from what– in discussions, you know, the, the limit of what you can actually ever measure on a good day.
Um, I just wonder, I mean, while those numbers, you know, €500, um, [00:26:00] million is a, is a big number, um, but what is that as a percentage of the overall output of that, of that facility? Um, I, I don’t know the answer, but, you know, if, if it’s, you know, half a percent, I think you’d be struggling to, um, struggling to justify that, that wake effect loss.
I mean, you know, going back to what you said, Allen, you know, there are wake effects of some sort, but it’s a question of how much. I mean, that-that’s why aircraft don’t take off, um, too closely, isn’t it? Because there’s wake effects. Um, so it’s definitely a given, definitely a given. Um, but, you know, how much of an impact it truly is.
Um, and I mean, there’s always other variables, you know, variables in the weather, you know, wind patterns, da, da, da, da, da, da, da, and how much do this– does this actually compare to those other, other variables?
Allen Hall 2025: Yolanda, how would you even mitigate wake turbulence on an adjacent wind farm? Are there ways to do that today?
Yolanda Padron: I think the, the aerodynamics, Allen, would [00:27:00] be a lot more in your court than, than in mine.
Matthew does have a really good point. I mean, what are we… With the UK wanting to ramp up offshore as much as they want to ramp up, right? They’re not going to just cancel a large project, and they need to… I mean, it’s not, uh, there’s a finite amount of space, right? So what, I mean, what, what are you, what are you gonna do?
It’s like, it’s what, like, what happens in onshore where you, you really hope maybe that you don’t get a wind farm that’s really, really close by. Um, but you might also want to plan for it. I mean, I know of sites that have le- that lease a little bit of extra land so that way no one else can lease it, or that they can, they can use that to, to travel between turbines.
Um, and it’s, I mean, it’s, it’s kind of… Isn’t it kind of just part of it, part of the trade?
Allen Hall 2025: it has to be, right, at some point. [00:28:00] The question in my mind about all this is how much wake is there? Is it directly impacting the adjacent wind farm? Is there– are there things that can be done to minimize that wake turbulence? I think the answer is yes, but as wind turbine blade designers, I haven’t seen the same level of wake reduction that we have seen more recently in aerospace.
It’s complicated to do some of these things on a wind turbine blade. You’re mass-producing. You’re making a blade a day or a blade in a day-and-a-half timeframe. Are you gonna design this really aerodynamic tip to go on to reduce the wake on a particular wind farm? Probably not, right? So it’s, it’s– is it worth doing that versus the, the cost it would be?
So it’s gonna cost 500 million euros in loss to an adjacent wind farm. Do you put that 500 million into the design effort and the molds and [00:29:00]everything else to make these blades different? Uh, it’s a tight trade-off, right? It– from the engineering side. It may be better settled in the courts, honestly. Just it may be cheaper to do it that way.
Matthew Stead: Uh, I, I was gonna go down a different avenue. I mean, obviously there’s always curtailment. There’s always curtailment due to grid congestion, et cetera, et cetera, et cetera, maintenance. I mean, if they, if they just– when wind is coming from a certain direction, they could just de-rate and, uh, just not absorb as much energy, um, out of the wind when the wind is coming from that sector.
And so that would be a way of, um, not modifying the turbine, just de-rating it under a certain wind condition. I mean, the same thing occurs with noise curtailment all the time. Um, so there’s, there’s noise modes. There could be a, a wake loss mode. We should trademark that
Allen Hall 2025: Well, you know who’s gonna make money out of this no matter what? The
lawyers.
Allen Hall 2025: [00:30:00] Well, in this quarter’s PES Wind magazine, there are a number of great articles, and you can download the entire magazine and all those great articles at peswind.com. There’s a nice little article from Enerpac Tool Group, and if you’re not familiar with them, they make a, a number of tools that are handy in the wind industry.
Uh, and, you know, routine torque checks is kind of a pain, right? And the problem with a lot of those checks is that you have to haul around a heavy hydraulic pump to do it. And so if you’ve ever been to a trade show and seen some of these [00:31:00] pumps, it is a pain. And if you h- have to move around, especially on a w- wind site a lot, you really don’t wanna have a heavy pump that maybe is made for something, uh, more robust.
Uh, and you need something that’s portable. That’s what you really need, right? So the Enerpac Tool Group has really created this, uh, LU series they call. Which is a lightweight, portable, hydraulic pump, which is for intermittent work, which is what happens on most wind sites. It’s intermittent. Uh, so the product line director, Angie Wallace, uh, talks about this and says technician feedback has shaped this new tool, uh, from multiple carrying handles and an upward-facing gauge.
And that is a big thumbs up from me. When you put the gauge on the side of the tool where you can’t see it, such a problem. It’s like they’ve never used it. Well, obviously, the Enerpac has been talking to technicians, and they put the gauge where the technician can actually see it. Uh, and it’s designed to go through towers and, and tight [00:32:00] spaces.
Uh, so this is made specifically for offshore conditions. It’s ruggedized, and it’s a great tool. And a lot of times, Matthew, when you s- see the technicians about and some of the tools they carry, you’re like, man, that is not a good tool for this. That is, that is too much to be hauling around, particularly uptower.
It’s nice that we can see some tools that are designed job
Matthew Stead: I, I’m completely convinced. I, I don’t have much to say. Um, I mean, my, my day job is, um, you know, designing products and working out what products we’re going to, to work on, and, you know, the customer is the main voice you should listen to, um, at least in the first step. So always listen to the customer first, and I think from what you’ve described, customer first, and then develop the product to suit the application.
Yeah, so yeah, I’m convinced
Allen Hall 2025: Yolanda, you’ve seen Interpack on sites, haven’t you? It does seem like I run across them once in a while at some of the US
sites
Yolanda Padron: Every once [00:33:00] in a while. I do gotta say I love the idea of when, like, actual, like, boots on the ground people’s feedback is taken into consideration for, for anything really. And so this is, this just makes me really happy because I think a lot of times, like, as engineers, like, we love the idea of just, oh, I’m gonna do this really cool fancy thing, and then it’s just it- no one can use it, or a very specialized person has to be able to use it.
And so actually doing, you know, modifying a product so that it, it makes sense for the people using it, and I know we’ve, we’ve all talked about it a lot internally and, and we continue to work towards making it easier and easier on, on the people actually installing the product. Like, this is, this is really exciting.
Allen Hall 2025: So if you need a lightweight pump for tightening some bolts uptower, particularly if you’re offshore, take a look at this Enerpac line of LU lightweight series tools. It’s well worth it. And at that same time, you should check out PES Wind magazine. Just go to [00:34:00] peswind.com
That wraps up another episode of the Uptime Wind Energy podcast. If today’s discussion sparked any questions or ideas, we’d love to hear from you. Reach out directly to Rosemary, and don’t forget to subscribe so you never miss an episode. for yolonda, Matthew, and Rosemary, I’m Allen Hall, and we’ll see you here next week on the Uptime Wind Energy podcast.
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