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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.
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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
Renewable Energy
Vestas Shares Jump 20%, UK Blocks Ming Yang Factory
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Vestas Shares Jump 20%, UK Blocks Ming Yang Factory
Vestas doubles second quarter profit and adds €4.7 billion in market value overnight. Plus EnBW finishes He Dreiht after a V236 blade break, the UK blocks Ming Yang’s Scottish factory, and India rules turbines are movable goods.
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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: Welcome to the Uptime Wind Energy podcast. I’m your host, Allen Hall, and I’m here with Rosemary Barnes, Matthew Stead, and Yolanda Padron. And three out of the four of us will be in Melbourne Australia talking to a number of operators and interested parties about WOMA 2027. Matthew, where will we be the couple of days we’re in Melbourne?
Matthew Stead: So, um, first of all, we’ve got the Pullman, uh, East Melbourne, which is, uh, where the venue will be for, for 2027. Um, so that’ll be our home base. Um, we’ve got around about eight meetings planned already. So what we’re doing is we’re talking to the operators and a few other industry, um, players about [00:01:00] what we need to talk about, how we’re gonna move the industry forward in Australia.
Uh, so it’s gonna be jam-packed, but there’s a little bit of time left on the Friday afternoon if there’s any late-minute, um, people that wanna get in contact and catch up with us, um, for next Thursday, Friday, or actually Friday. Uh, so yeah, it’s gonna be a, a jam-packed time. I think we’re gonna be tired, too many coffees, and talking to all the key, all the key operators, uh, about what they wanna hear about and how we can move the, the industry forward.
Allen Hall: And if someone wants to put an input into the WOMA panel about what will be discussed at WOMA 2027, Matthew, how would they do that? How do they get ahold of you?
Matthew Stead: Well, we have a wonderful website, and that’s got all the details you could ever want. Um, you can also register on the website, so please register.
Otherwise, um, I’m sure we’re gonna be a sellout this year for sure. So woma2027.com.
Rosemary Barnes: I just wanna add that when people talk to [00:02:00] me about the event, they always say how they love that the topics are so relevant, and the reason why that they’re so relevant is because we make sure to go around to operators and find out what are the issues that they’re really dealing with.
So anybody that’s thinking of attending, even if you can’t, you know, meet us up, meet up with us in Melbourne, get in touch and tell us what are the, yeah, what are the topics that you’re struggling with that you’re not, um, you’re having trouble finding enough information, having trouble finding the people that can help you.
And y- yeah, like we take all of that information, and that’s how we come up with our agenda each year. And yeah, I mean, for us, that’s the, the main thing is that this has to be really relevant, up-to-date information for the industry, and we need your help to make sure it stays that way. I
Matthew Stead: mean, that’s what we’ve done the last two years, so this is– we’re just repeating the formula, um, listening to the operators and getting the good topics and the good speakers.
Allen Hall: Well, Vestas has had a good quarter. Uh, the, for the last couple of years, honestly, s- [00:03:00] Vestas has been really thin on margins. There was questions about it continuing on. Rising costs mostly, uh, supply chains, especially during COVID, were bad. Uh, and, uh, but for the most part, the shareholders stayed attached.
Well, that story is changing rapidly. The world’s largest turbine maker posted second quarter operating profits of $400- €46 million, more than double what the analysts had expected, and it’s raised its full-year margin guidance alongside half-year results for the first time in a decade. The shares climbed about 20% in Copenhagen, adding roughly €4.7 billion of market value in a single session.
Now, the chief executive, uh, Henrik Andersen, ha- put it plainly to, uh, uh, in a couple of news sources that something much bigger is happening and Vestas is gonna be the, the leader in wind. That’s how I read it, that everybody [00:04:00]at Vestas was super happy with the, the change in direction and things were moving up steadily.
But a 20% jump in a day is remarkable. You don’t see that in large industrial businesses like wind energy. Matthew, this has real implications on what happens next for Vestas because success like this usually means more orders.
Matthew Stead: Yeah, I wonder what’s going on under the hood there. Um, I mean, Vestas is a quality company, although, although can I just do a quick segue?
How many turbines were installed in Denmark in the last, uh, two years? Like last year and the year before?
Allen Hall: I don’t know. How many?
Matthew Stead: I believe it was eight turbines installed onshore in Denmark last year, and the year before it was 12. So, you know, maybe, maybe Vestas needs to focus on their own backyard a little bit as well.
Allen Hall: I’m not sure there’s a lot of opportunity there. Yeah, onshore.
Matthew Stead: How can you ever be full? I mean, there’s always, um, [00:05:00] uh, you know, um, you know, resiting or, um, you know, upgrades and-
Rosemary Barnes: You know what? Allen and I are probably gonna get some time in Jutland, uh, later this year, um, and that area and the old wind turbines there was actually the inspiration for my whole YouTube channel.
It just, ’cause there’s, you know, there’s turbines there from, the earliest one is, um, from the ’70s and still going. I think it’s one and a half megawatts, actually huge for, for that time. Um, and it was like community made, um, at Tvind. But anyway, I’m interested to revisit the site and have a look and see are these, you know, all these old turbines still there.
It’s only, like six years since I went through and did the experience but for the most part, they don’t seem to be yet pulling down the, the small old ones and putting up big ones. There’s a lot of, a lot of them are community owned. Um, and yeah, I mean, Danish people love wind turbines, but there’s only so many that you can have onshore.
Like, people are happy to live near them by, you know, the standards of people in other countries, but you don’t want [00:06:00] one in your literal backyard. I think that there is, there, there is a, a limit to how many more onshore wind turbines that you can get in that area and offshore expansion is the more likely way to go.
Um, and also I think it’s, it’s, it’s good to recognize that if you have a domestic only or a domestic first strategy, that will only get you so far and then you have to expand, and I think Denmark did that really well. I think Germany a little bit less. I think that Enercon were a bit surprised, um, by their strategy.
It, uh, they had a real hard time anyway when they had to transition away from mostly Germany to getting overseas. And obviously, like if you look at China, they have most of their installations are in China. They are trying so hard to get outside of China because it’s not, like even a market as big as China, it’s got decades to go before it will be full.
Um, you can still recognize that that’s not your, like long-term strategy for growth has to involve expansion, I think.
Allen Hall: I think Vestas, regardless of what happens in Denmark, is making a play for the United States. That seems to be [00:07:00] where a significant effort is happening at the moment and on offshore. Their– Vestas seems very excited about the offshore opportunities.
Of course, there’s a ton of wind turbines gonna be installed in the UK and, and all around Northern Europe. Offshore, the opportunities to buy turbines, there’s only a couple that you could get today. Uh, uh, the GE Vernova offerings I, I don’t think are gonna fit the mold, and I don’t know if GE’s even actively selling.
So their competitor realistically is Siemens Gamesa, which does seem like the smaller player at the minute versus Vestas, which is heavily pushing the V236 and will fill order books like crazy, I think, uh, just based upon the, the history they’ve had and everybody knowing who they are. So Also on the move in Australia, right?
Vestas is huge in Australia right now.
Rosemary Barnes: I think it’s really good that their, um, yeah, finances, uh, are [00:08:00] looking a bit better ’cause it’s been funny. Like, I tried early on in my wind career to invest in, you know, wind turbine manufacturers knowing that there would be immense growth, and I was right. There, there was immense growth.
Not that that was so hard to figure out that there would be, but it did not lead to any kind of, um, return on, on anything, you know. Like, that did not keep pace with the just general market. Um, so I, I stopped trying to, stopped trying to invest to that. But it has been really, really hard for the companies to, you know, raise money or y- you know, do any of the things that they need to do because they’ve always, like, they’re growing, growing, growing, but finances has been so tight that it has been a real constraint on the amount of engineering that they could do, and I really hope that Vestas are gonna take this opportunity that they’ve got compared to, you know, a lot of the other manufacturers.
Vestas do have really strong, um, innovation and, yeah, engineering capabilities for doing– you know, developing new technologies and improving them, and I really hope that they’re taking this opportunity to build that up. There are a lot [00:09:00] of very good engineers with a lot of experience in the industry in that area that are working in other fields at the moment because, you know, there’s been a lot of contraction in Denmark.
So I don’t know, it seems like a really good time to hire back some of that really in-depth knowledge and, yeah, get a- get ahead of, you know, some of the future quality problems. We’re going through such a hard time at the moment from the fast development that happened in the 20-teens when there wasn’t a whole lot of money around.
We’re dealing with quality problems now, so, you know, maybe we can get ahead and not have the next round of them if we can invest in just a lot more, uh, engineering capacity.
Allen Hall: When you have success like Vestas has, usually the upper level management and some of the executive team starts getting pilfered, that they’ll get offers to repeat that success at another company, and it sounds like that process has started already.
There’s a couple of executives that have recently departing or are in the midst of departing from Vestas. [00:10:00] I would see that continuing f- at least for the next six months, uh, because everybody wants to repeat that, right? If you can get a 20% increase in your valuation overnight, uh, I can, I can list a number of companies, regardless of industry, that would love to participate.
Even in a 5% increase, that would be remarkable. So, um, Vestas is gonna have a hard time holding onto this. That’s just the nature of the business where things are successful, people will wander. And Rosemary, I, I think they’re– And Yolanda In, in my book, Vestas should sort of s-stand down and just make quality products.
I’m not sure you sh-should tinker too much at the time being and just make the good stuff better. That seems like a way to really increase profits.
Yolanda Padron: Yeah, I mean, solving a lot of the issues that– And, and that’s not just a Vestas exclusive thing, right? All of these OEMs have some sort of issue that maybe– I know Rosie’s touched a lot on, on it, where [00:11:00] you build this version A and then version B solves one of the small little issues, but now it creates another little problem, and then you have version C, and then everything just kinda has its own niche little issue, um, that really expands over time.
So if they could solidify what they already have in, in a, in a model that, that would help them just even keep a lot of their customers, I think that’d be great, and it would help, certainly help them, um, not continuously, like, rotate around the customers, ’cause it almost feels like, at least in the States, right, you, you get GE to be really, really strong and have a huge market share, and then GE starts focusing more on gas turbines, so then they all go onto Vestas, and then they all go onto Ontara now.
Um, and then just, you know, just kind of everybody starts cycling through them because they just kind of want something that’s better quality than what they’re getting in the long haul.
Matthew Stead: Allen, you, you talked about you think there’s something big under the hood. I think you, you [00:12:00] thought that maybe Vestas was angling towards something or being quite bullish.
Do you think that they might take over GE Vernova?
Allen Hall: I don’t think they’re gonna grab Vernova, and I don’t think Vernova is for sale at the minute, but I wonder if Siemens Gamesa is, or Nordex. I mean, Nordex has done terrific the last couple of quarters and is making inroads in places that I didn’t think possible three, four years ago.
Uh, the European marketplace is be- becoming really unique in that sense that there’s a lot of money being put out. But is there a sole perfect solution for Europe? Not at the minute, ’cause you got two competitors there, and then China trying to, to work its way in. Will the Europeans come together and form something more united, even if it’s just a partnership, a loose partnership, versus letting China on the shores?
We’ll see. 64 of the largest machines that Vestas has builds are standing off the German coast, but one blade is missing a [00:13:00] piece. We’ll talk about that when we come back.
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Allen Hall: Well, Germany’s largest offshore wind farm is now fully installed, and EnBW confirmed this, uh, past week that all 64 of the Vestas V236 15-megawatt turbines are s- standing at the He Dreiht wind farm about 85 kilometers northwest of Borkum. Uh, 960 megawatts, [00:14:00] 2.4 billion euros invested. Man, these offshore projects are expensive to get installed.
Uh, so it’s power for roughly 1.1 million households, and there’s no state subsidy behind any of it. And so this is a little bit of a u- unique situation. Uh, th- well, the one footnote about the wind farm is they had a V236 blade break and fall into the North Sea, and they had fished it out and I think I passed along s- pictures that I saw online of, uh, one of the police boats pulling the shear web out of the water I don’t know what to think anymore about some of these offshore blade issues.
Obviously, Vestas is very conscientious about it and will be doing RCAs and engineering reviews and all the above to go identify what the problem is. But it does just lead to a little bit of a pause of do– what is going on for some of these offshore [00:15:00] wind blade installations or, or whatever’s causing these blades to break?
Do we have a good handle on it? Yolanda, is– are we following up on all the design details so that we can prevent these things in the future?
Yolanda Padron: I mean, I’d, I’d hope you’d be following up on the design, right? Like, and, um, but I think there is still a little bit of a disconnect from, from what we’ve seen, and again, not just Vestas exclusive, um, between the people who are designing and the people who are manufacturing, the people who are in operations, right?
So, uh- The, from what we’ve heard, uh, this could have potentially been a, um, partially because of a transportation issue, which is what happens a lot in onshore. It’s a lot more common than we would like it to be. Um, and so that even goes beyond what would go on in the design studio and what would go on in the manufacturing and what would [00:16:00] go on even just for the people that are running the site, right?
So, so some sort of, um, in between, uh, EPC error. Um, but yeah, I just think that, like in a lot of industries, there should be a lot more communication between all of these teams on the lower level, so that way a lot of these problems can, can be avoided.
Allen Hall: I’m wondering if it’s actually an issue on the, the testing side.
And, uh, the one question that just popped up, and we saw from the ORE Catapult, uh, survey that’s being conducted at the moment, and if you haven’t participated in that, you just visit ORE Catapult and answer some of the survey questions. But torsion on a blade, which is very difficult to test for, and it really isn’t tested for today, but does happen during the move and the transportation of these big offshore blades.
Is it one area that we need to do a little more work in or maybe spend some more time focusing on it to see what is happening as blades are [00:17:00]moved?
Rosemary Barnes: The thing about te- torsion is that it is much more significant as blades get longer. I can’t, I can’t remember the equation off the top of my head, which is, um, bothering me.
But I think it scales with, like, the fourth power or something of, of length. And so whilst it was always a bit of a problem, it’s much more of a problem as it gets, as blades get bigger. I mean, they’ve never, like, fully tested a blade, and there was always a lot of reliance on, hey, y- you know, like we’ve tested certain things that is possible to test in a test facility on the ground.
But they also rely on their decades of experience of how blades actually behave in the field. But, you know, remember, that’s a real lagging, lagging indicator because y- you know, their decades of experience is mostly with lots smaller blades. Now, blades are really different because they’re longer and different effects are, are taking over.
It’s not just, uh, torsion, but it’s also the laminates get much thicker, and then y- you know, you, you have issues with the way that they’re curing, [00:18:00] and there’s a lot more just space for, um, defects to be present in a really thick laminate All of those things add up. Oh, yeah, then add in addition, like new materials, carbon fiber is new, and then new ways of producing it, you know, pultrusions, um, all kinds of different materials like balsa’s being replaced with foams and, um, like, you know, 10 times that number of what sounds like a small innovation, but all of these things have the potential for damage and don’t have a really long track record in the field to be able to kind of calibrate.
We do need to remember that, like, when you do something new, things are gonna break, uh, sometimes, they’re gonna fail sometimes. If they don’t, then you’re definitely being too conservative, and your product is costing more than it should, and nobody wants more expensive wind energy, right?
Matthew Stead: Rosie, Rosie, I, I know you’re doing some, some excellent work on, um, industry studies around erosion and temperature and so forth.
Um, I just wanted to let a little secret out of the bag that, um, in the future there will also be some [00:19:00] other studies on torsion and blade twist and blade dynamics. So, um, just a few things are in, in train at the moment, which I can’t share, share, but, uh, watch this space around better understanding blade twist.
Allen Hall: The Hydride wind farm runs on European turbines, but the next one might not. Two governments with two very different answers on who gets to build Europe’s wind fleet.
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Well, two countries and two decisions, one question. In Scotland, the UK government blocked plans for the Chinese manufacturer Mingyang to build a turbine factory, uh, near Inverness on national security grounds. 1.5 billion pounds of investment, up to about 1,500 jobs. And First Minister John Swinney has asked the new prime minister to reconsider.
And the UK energy secretary minister called that request irresponsible. Meanwhile, up in Denmark, Vattenfall has just won two offshore wind farms and will not say whether it will buy European turbines. Danish suppliers are not taking that quietly. So [00:21:00] the Scotland question about the Mingyang factory is at least being discussed again with the new prime minister in the UK.
It does seem like there’s a lot to do and get the government formed and make all this stuff happen. But I don’t see a Burnham administration changing the outcome for Mingyang, but I could be wrong. At the, the same time, Vestas is pushing for a more Eurocentric focus and to really keep out the Chinese.
Uh, something has to give here pretty soon.
Matthew Stead: I actually think Mingyang should, um, set up a factory in Scotland. I, I mean, what’s wrong with that? I mean, uh, why is that a security issue?
Rosemary Barnes: Set up the factory and put the, like, whatever you’re worried about, put protections in place for it, require it to be a local joint venture or whatever.
You know, we’ve seen the blueprint in many of what used to be, you know, less rich countries. That’s how they, you know, got a head start on some of these technologies. It’s not like, I don’t think that China [00:22:00] has a head start on wind, wind turbine technology, but they certainly have different ways of doing things that, um, yeah, we could, we could learn from.
But I think across the board, wind turbines, batteries, solar panels, whatever, let them set up factories, put the rules in place that mean that your country benefits from it and you’re getting the, you know, the information transfer.
Yolanda Padron: Do you think that’ll, like, impulse a lot of these more established European companies to maybe start fixing some of the issues that they’ve known about for, for a while, um, particularly regarding the blades and everything that we’ve talked about earlier?
Like, there’s enough competition there, so maybe they need to start looking a little bit more deeply into their problems.
Allen Hall: Do we think that Chinese operations have been out front, forward, honest, I’ll even use, about their blade issues?
Rosemary Barnes: No, but this is a good way to find out, isn’t it?
Allen Hall: Governments decide who is allowed to build a turbine after a discussion on Scotland.
Uh, but, but [00:23:00] occasionally, a court decides what a turbine legally is. India has just settled that question, and the reasoning should be of interest to anybody who ships machines across a border right after this. As wind energy professionals, staying informed is crucial and let’s face it, difficult. That’s why the Uptime Podcast recommends PES Wind Magazine.
PES Wind offers a diverse range of in-depth articles and expert insights that dive into the most pressing issues facing our energy future. Whether you’re an industry veteran or new to wind, PES Wind has the high-quality content you need. Don’t miss out. Visit peswind.com today. A tax fight in India has produced a definition every turbine supplier should read.
Is a wind turbine bolted to a concrete foundation movable goods, or is it immovable property? State tax authorities argued immovable, which would have [00:24:00] taxed erection and commissioning contracts at 18% instead of 5%. The Andhra Pradesh, uh, High Court disagreed, and on the 12th of August, the Supreme Court declined to interfere.
The reasoning rests on something this whole industry takes for granted. A turbine can be taken down, moved, and put back up. So a turbine is a movable object, and it has less taxation. Bonus. So this is a really interesting discussion that’s happening in India because it’s probably symptomatic of things we’re seeing elsewhere across the world about taxation for wind turbines, right?
That, um, if there’s a way to tax a wind turbine, we’re gonna try to do it. This is a unique way, uh, that happens in India where depending on if it’s permanent or movable, the tax rates are different. I, I guess that would apply to a lot of components inside a wind turbine too, Matthew, don’t you? Like the, the generator, the, the big heavy things, [00:25:00] gearbox, generator, blades, rotors, tower sections, would be taxed at a, a lesser rate.
Matthew Stead: I agree with the court case that it’s all movable and, uh, you can actually buy turbines on the secondhand market, can’t you? I mean, if I wanted to buy, yeah, whatever, whatever, I could buy one and, and put it up in my backyard if I had a bigger backyard. Um, so yeah, I vote for movable. I vote for lower taxes.
Yolanda Padron: The way that it would work a lot of times in the US is, I mean, it’s, you pay, the company itself pays a lot less than they would’ve over time, right? Just by pure, the, the regular kind of tax laws. Um, but the community, there’d be just direct donations to the community, so then they’d get, uh, like money would actually come into the community where the turbines were being built instead of just distributed around the state, which I mean, in a state as big as Texas, it gets, um, but easier for that c- um, that county to get a lot more, uh, funding than they would typically get if it was [00:26:00] through a big enough area.
Um, but yeah, no, I agr- I completely agree with you guys that, that this should be a movable good. I mean, how many times have we seen, uh, even just a blade, um, that it looks like it’s, uh, just a, a failed blade that they have to go in and replace, and then they take it out, fix it, and then just bring it back to the same site or take it to another site across the country.
And, and to that point, like if you were to h- judge it as something that’s immovable, would then any blade replacement just not be taxed? Because then it’s, you’re moving that one component and two, but it’s essentially the same turbine. Like, I don’t know how that all would make sense.
Allen Hall: I think the Uptime Supreme Court agrees with the Indian Supreme Court that wind turbines are movable, and that’s good.
Well, 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. [00:27:00] Reach out to us on LinkedIn. And if you found value in today’s conversation, please leave us a review. It really helps other wind energy professionals discover the show.
And don’t forget to subscribe so you never miss an episode. For Rosa, Yolanda, and Matthew, I’m Allen Hall. We’ll see you here next week on the Uptime Wind Energy podcast.
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Vermont and Florida: A Key Difference
Can’t swear that the story here is authentic, but it sure rings true.
Vermont is a somewhat quirky state, but it protects its citizens very well. FWIW, this is where I want MY tax dollars going too.
Florida is a deeply red state that, true to form, wants as much ignorance as it can possibly produce. Educated people aren’t voting for people like Ron Desantis.
Renewable Energy
Republicans: Will This Work?
The GOP is asking American voters to believe that “radical left Democrat extremists” are leading the country into socialism/communism. They’re hoping that this fear will outweigh the electorate’s understanding of the damage that Trump, with help of congressional Republicans, is inflicting on this nation in the form of the war in Iran, destroyed relations with allies, inflation, shoddy education, environmental collapse, and threats to Social Security and Medicare.
As we all know, the rate at which a lie becomes accepted as true is a function of the frequency that it is repeated. And God knows, we see this crap about communism every time we turn around.
But this looks like an unwinnable battle. Virtually no one wants to abandon free enterprise. Moreover, Trump’s abysmal polling numbers reflect the fact that is largely despised as a criminal–the most corrupt figure in U.S. history.
How would you like to be campaigning to retired baby boomers on the platform that we cannot afford Social Security any longer, because we’ve siphoned off huge amounts of money, like our president’s “vanity war,” with only further downside in sight, that is costing $1 billion a day?
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