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Localizing Offshore Wind: Insights from KIMA Energy’s Maya Malik
Maya Malik, co-founder of KIMAenergy, joins host Rosie Barnes to discuss local content in offshore wind. Drawing on examples from the UK, Denmark, Japan, Taiwan and Australia, they explore policies to encourage domestic manufacturing. Maya shares insights on the key factors for success, including providing certainty on project volumes, offering incentives and infrastructure, and exploiting the potential for low-emission manufacturing in Australia’s growing offshore wind industry.
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Rosemary Barnes: Welcome to a special episode of the Uptime Wind Energy Podcast. I’m your host, Rosie Barnes, and I have with me today, Maya Malik, who is the co founder of KIMAenergy. Thanks for joining us, Maya. Thanks, Rosie. Happy to be here. So today we’re going to be talking all about local content and how countries can try to get more manufacturing in their region when they’re going to be installing a lot of wind energy.
So I know this is an area that you’ve worked in a lot. Would you be able to just give us a bit of background about the kinds of work that you’ve done in this industry over the years?
Maya Malik: Yeah, sure. So I have a 20 year background in energy and offshore wind. Actually I first started in, in petrochemicals working in Australia and Europe and Asia.
On the construction projects and 13 years ago, I moved to offshore wind. So I worked on projects in the UK, in Europe and Asia. And then together with my business partner, we started up KIMAenergy, which we are an advisory company focused on offshore wind in APAC. And I guess our niche is doing offshore wind in new markets.
For most of our careers, we’ve basically worked on projects that are, pioneering in nature in the countries that we’ve worked in. Now we are based in Melbourne and yeah, continuing to support other developers with their projects in new markets.
Rosemary Barnes: Okay. So you’ve worked a lot on a lot of different offshore wind projects all around the globe. I know that from the conversation that we’ve had before, before this recording. Can you tell me about yeah, just a little bit of A few examples of some interesting offshore wind projects that you’ve worked on.
Maya Malik: Most interesting and I guess most impactful for me was working on projects in Taiwan. I’d worked on projects in Europe but there, the industry developed quite organically over, a period of two decades projects, getting incrementally bigger and technology incrementally improving.
And Taiwan, I would say was the first market outside of Northern Europe to implement offshore wind and also was doing it in a way to accelerate the industrialization. So go from, doing commercial scale projects over a period of multiple years to, a handful of years. Yeah I I moved there together with another colleague from my company, and we were essentially there to win projects and, do a show in for the first time in in Taiwan.
And yeah, it was a really It was a cool experience. Yeah, just really not having, the suppliers, not having the experienced people on the ground and just, it was down to, you and what you knew and, the resources you could personally call on. To do to do projects.
Yeah, it was a real growth experience, I think for all of us in the industry at that time. But yeah, super, super great achievement.
Rosemary Barnes: You’re Australian, but you started in Australia. And then Europe, you’re in Denmark. Is that right?
Maya Malik: I was based out of the UK working for the main Danish utility.
So yeah, that was my second home. And then, I guess. Denmark did offshore wind, they were important in the innovation of the technology, but UK were the ones to really take it to a commercial scale. So put the policies and targets behind doing offshore wind at volume, allowing it to industrialize.
And then the next market to do that would be Germany. I was quite involved on those projects as well. And then we started looking outside of Northern Europe. Yeah, there was an important period in 2017 when the auction price for Osherwind showed that, the LCOE was cheaper than gas.
And then it really changed everything. And in our industry and I would say exploded at that point and then, yeah, and then the first market that, that would move to implement offshore wind fastest was Taiwan. And for me, it was, I’d lived in Asia before and I loved it and it was closer to home.
So a great chance to do lots of things and tick many boxes.
Rosemary Barnes: Okay. And now back to Australia where we’re only just getting into gear now. Can you talk a little bit about Yeah. What’s going on with offshore wind at the moment? I think a lot of our listeners are based in the US so might not be a hundred percent familiar with what’s going on in Australia, but yeah, it’s an exciting time.
Can you, yeah, to summarize where we’re up to now? Yeah, sure.
Maya Malik: So yeah, it’s a kind of, it’s a late market, quite an immature one, but actually they. did a fantastic job to very fast put in place the framework to award seabed rights. And I would say, the framework they put together is amongst the clearest I’ve seen globally.
So it was very, transparent and easy to understand what you had to do to secure exclusivity for your offshore area. So Australia is following a two stage process to award project rights. So first, there’s a competitive price to give away CBAD exclusive rights for CBAD area. And then there’s a second process to give support for revenue.
So this will be similar to U. S. and other countries like U. K. and Korea. And the process towards CBAD rights is done by the federal government. So they do it across all states in Australia. Yeah. And they have essentially looked across the states, where there’s developer interest, where it was viable to do offshore wind and where there was supporting infrastructure that could be developed by Carbis.
And they basically narrowed it down to six areas. And they have released what they call a draft declared area for all sex and some are starting to be finalized. They also have released invitations to apply for what is called a feasibility license, which is essentially your exclusive right to develop in an area.
And yeah, the first licenses have just been awarded weeks ago for an area in the state of Victoria called Gippsland. And I think the second area will be in New South Wales that will be announced soon. And then the next step, awarding revenue, is going to be run by the state government rather than the federal.
So there’s limited information on the regime and exactly how it will work, but it’s expecting that it will, be very similar to the UK CFD regime.
Rosemary Barnes: Yeah, so the, they’ve announced six, six areas right in Gippsland. And then I saw that there’s another six shortlisted. And I was a bit unsure about what happened there.
Did the government like divide up the area into parcels of, I want to always want to say land, but I guess parcels of seabed and let people bid on them. Or was it up to developers to pick what they thought would be a good spot and then choose exactly which area. First zone
Maya Malik: has awarded licenses. So this is a zone of Gippsland.
And then 12 licenses have been awarded in Gippsland. Yeah, equivalent to about 25 gigawatts of offshore wind. And of these 12 licenses, six are confirmed and the other six are in the process of being confirmed. Yeah, then in terms of how it, how the framework is designed and how you select and are awarded your sites.
So what the government does is initially announces a declared area. An issue is an invitation for developers to apply for a feasibility license. And for Gippsland, the area was 15, 000 kilometers squared and each developer could apply for as many licenses they want. Each license was allowed to be up to 700 kilometers squared in size, supporting about two and a half gigawatts of offshore wind.
And then, the process to decide. Your license area was up to individual developers. There was no coordination and there was also many prerequisites. So in other markets, you might need to pre qualify by having certain consents and so on. But here it was essentially you were. To write a proposal that showed, your technical capability, your financial capability, and also how you would benefit the economy.
And then based on that application and the area you chose, government took that and made their assessment over a period of around eight months and they first decided who would Met the minimum merit criteria. So they had a criteria, financial ability and if you met merit criteria and put into the next level, and then they reviewed who overlapped with who, and then if you’re, if you met the merit criteria, but you overlap with someone else who also met it, then the government has a kind of discrepancy to decide who has more merit.
And awarded to the person with more merit. So it’s a little bit of luck in this, if you choose an area that no one else chose, then. Then if you meet the minimum bar, you’re probably getting a license. But if you meet an area that a lot of people chose, then it’s going to go to the person who is deemed, yeah, is the best developer according to the government score sheet.
And then in some cases they could say you were equal in merit. And then they would put you into a private negotiation to decide how to divide the area that you overlapped.
Rosemary Barnes: Okay, but there was no auction or anything, like they ran in New York?
Maya Malik: No, so there were, the regulations did allow for if if the two developers that were put into a negotiation couldn’t agree, it did allow the government to ask for each developer to then submit a price.
And then the highest bidder would win that area. But of course, all developers would like to award that. And then there was yeah, that did not happen in this case. It could happen in future. But essentially yeah, it’s quite a cheap process compared to other markets where you need to, Commit to and pay for a seabed lease.
This is this is not, you’re not getting a lease either. So the rights aren’t as firm as in other markets where you get a seabed lease in return, you just get a right to do your surveys and progress your development works, but you’re also getting that right exclusively. That as long as you progress the works and get it to the next stage.
No one else is going to be able to do the same for your area.
Rosemary Barnes: It sounds like a lot, right? Up to 25 gigawatts just in this first region. Any crystal ball gazing about how many of these projects will eventually go to fruition? And when do you think the first ones will start to come online? If
Maya Malik: you step back and look at Australia, they’ve released a lot of seabed.
If you add up all these declared areas, it’s around 100 gigawatts that it can support. And consider that Australia, the full installed capacity in Australia is 80 gigawatts. That’s a lot. And what I found quite interesting is more than half of it is for floating which is, going to have higher end costs and further away.
And considering Australia also has lots of onshore energy options. And here it puts a question mark against, right? So what is actually going to be built out of all this seabed area released? That is the magic question. And then if you just look at Gippsland, so you had this, 15, 000 kilometers squared.
So now what’s awarded in licenses is a lot less, but still 25 gigawatts. Then if you look at how much grid connection capacity is being allocated and built out, That’s seven gigawatts. Then if you look at what the state target is by 2040, that’s nine gigawatts. So it’s allowing for also some to be offshore wind to be done on the other side of the state where they also have a declared area.
So of the 25 gigawatts, seven gigawatts can be connected to the grid. At least with, with the plans that are around today. Yeah, you are having still quite a lot of competition and I think like particularly in the auction stages, it will be highly competitive.
I think it’s quite interesting at the 25 gigawatts. Also, a lot of that is floating. and naturally not be as competitive in an auction. So it’s I’m not sure how they would, Like when I’ll participate unless a separate regime is created to support that technology.
Rosemary Barnes: Okay let’s move on a little bit because the main thing that I wanted to talk to you today about was the manufacturing associated with having such a, huge potential pipeline of offshore wind projects.
Another recent little bit of Australian. government action in recent weeks was this future made in Australia announcement from the government that they’ve got, like a lot of money set aside for manufacturing renewables and energy transition stuff in Australia. There’s a lot for hydrogen.
There’s a lot for critical minerals that then I think. It’s all kinds of clean energy in general. Yeah. So I just wanted to talk to you about what does it take to actually get manufacturing happening locally? And I know that this is something that you’ve been working on and you’ve seen other countries like Taiwan, let’s start with them as an example.
What did they do to, when they, wanted to start up an offshore wind industry there, what actions did they take to make sure that industry also brought manufacturing industry with it to the country? So currently
Maya Malik: you have just one state really committing to offshore wind by putting it into the energy mix.
This is Victoria saying they do nine gigawatts by 2040. And then, yeah, you have a lot of seabed being given away. It’s still not really clear how big the industry here is going to be. And and will there be appetite in other states to support the grid upgrades and the offtake regimes that you need to realize projects.
So in my view, until the industry or suppliers, can be confident about the volume and the timing of offshore wind build out in Australia, it’ll be really difficult for them to invest into manufacturing new facilities. But I think if they could see this or get this certainty, I actually I’m not as pessimistic as most Australians who are beating themselves up constantly about how bad we are at manufacturing.
I actually think there’s a lot of potential and a lot could be done here. I really think the key thing, to address is this volume and certainty of projects because that’s when you get manufacturing.
Rosemary Barnes: Yeah, you definitely see with offshore wind around the world when there’s big projects that set in stone, then you do start to see factories opening because the components are huge, right?
It’s over a hundred meters long and all the. Substructures are large as well.
Maya Malik: And it’s so correlated. And let’s look at an example in the UK, you had the industry sector deal in 2018, 2019, this is between industry and government. And government essentially saying, we want lots of local content.
What’s it going to take, and what agreements can we make around, developing local content. And, the agreement they came to is okay. Developers will aim for 60 percent local content. Starting from where they were in the twenties and thirties. And in return, government would provide a 40 gigawatts pipeline.
Volume of projects and, steadily releasing X amount per year with, CFD regimes behind it to support. And, and then behind that was a number of other things like supporting the upgrade of harbors and tax reliefs, et cetera. But yeah, in essence the top level, give and take there was you give us 60%, I’ll give you volume as it, you can really break it down to that.
And yeah, for me, that’s, that kind of piece is still missing. So it’s hard to move on to the next and then, because I think if you look at what we have now existing, so it’s not a lot of specialist vessels and a low manufacturing base capability. Okay. Thanks. So to get to that next step you need investment and you it’s hard to get the investment without the volume, without the contracts.
So that’s the sort of yeah, thing to aim for. And then you have these other enablers, grants, tax reliefs, et cetera, that all help, right? All help to pull it together. So yeah. And I guess I can also add looking at the current situation we did in the last project I was on, we did quite a detailed local content study for offshore wind in Australia.
And I found in summary, what it showed was actually the skills here. Really high quality and absolutely the right skills given our parallel heavy industries to do a lot of stuff locally. And then, yeah, the limitation is facilities quayside space, so harbors that can support manufacturing and specialist vessels.
And so that leaves you in an area because you’ve got all the right skills of people. So we’ll do great in, development phase in operations and maintenance let’s say in civil structures. So yeah, you have very high local content and job creation where it’s more dependent on skills and people.
And then you have, some scopes that are dependent on manufacturing and specialist vessels, like the turbines, foundations, installation, cables, the local content quite limited. And yeah, it needs a, it needs an investment.
Rosemary Barnes: And what are, what other models are being used around the world?
I know that when we talked before, you told me about. The approach that they took in Taiwan, for example, that was really different to that. It sounds like in the UK, it’s more a matter of, provide certainty. Manufacturers are going to want to put factories there just because that’s the most logical place to supply these huge components.
But that’s not. That’s not what Taiwan did, right? They took a much more micromanagement approach. I don’t know if that’s the right word. So I think UK
Maya Malik: is what I would call like a soft local content policy. And interestingly, I’ll go incrementally, so UK, quite soft I think they were also quite late and they were also stuck to a model for instance, when it came to developing harbors, very keen on more promoting private sector investment.
Rather than government led upgrades, which is something let’s say Denmark did, and therefore did it much faster and we’re able to capture more manufacturing opportunities despite not having a low, a big local pipeline. So yeah, one thing you can do is soft policies and give industry like a clear signal that this is what you want.
And then, those that, toe the line will get the projects and then then you have, the countries like Denmark, which is more focusing on what enablers, can I put in place and it’s a form of subsidy and they just, built a really, good, big harbor that was well placed and could support, industry and attract people to set up facilities and so on.
And therefore, despite not having their own project pipeline who could capture the opportunities in the region. Then you have someone like Japan and they have a sector deal as well. So similar to the UK got together with industry and said, okay, we would like 60 percent by I think it’s 2040.
And also gave grants for, setting up plants and factories and. And then took it a bit step further. So then also made it part of the auction process. So it’s part of the auction. You submit a proposal and percentage of score is your price and the percentage of your score is also your contribution to the local economy and your collaboration with local stakeholders.
It it’s the. Becoming a bit more, hard requirements, but still giving developers a lot of flexibility about how they do it and also how much they want to do. But then obviously the more you do, the better you score. So you have a much better chance of winning a project.
Then then we’ll go to Taiwan. And I guess they’re on extreme end. After doing their demo projects, they created a scheme. If they had the. Selection process followed by an auction process and the selection process was very much around, attracting global developers to, to come to Taiwan and, essentially make sure offshore wind happen.
And then the selection process, the reward was a very high feed in tariff. And you weren’t required to submit a price that was predetermined, that tariff was your carrot at the end. And there was a qualification criteria, which you had to promise to meet a certain amount of local content, and then you were also invited to submit a proposal that showed, how.
Great, you were technical, financial wise, but also gave you opportunity to offer even more local content. And then, person with the highest score wins and, you get a high score by offering more local content. And then this has evolved through various rounds. So in. In the very first selection round, the first project, they wanted to prioritize fast delivery, low complexity.
So they said, you guys get a break from local content. And then there was another three gigawatts that were awarded with grid connection dates, across several years. And the earlier ones had to do less. And the ones awarded with later connection dates had to do more. Ironically, this ended up in a situation where you had quite a small volume of projects that had to do the most local content.
And then therefore the contracts for these local content were quite small in nature and didn’t have the volume of pipelines ended up being very expensive. And yeah, you have this trend of, instead of cost going down cost going up. Then then you had a period of a, then you had an auction for another couple of gigawatts where they took away all of the content but they’re expecting that they had, already had enough pipeline that local content would naturally happen, but it wasn’t quite there.
And because it was so expensive, um, it wasn’t the natural choice. So then when they brought in the next auction. They, um, they didn’t make it mandatory, but they made it a competition of local content. So who can deliver the most wins? And it’s gone through various iterations because so many developers are struggling with it.
And yeah, and I would say regrettably in Taiwan, so now they have several gigawatts of projects. But. The costs there are increasing and continue to increase. So, yeah, it’s it can, it’s started to concern investors and some people have exited the market. And it, because like this increase in the content and costs is combined with reduce.
Subsidies and support on the revenue side. So there’s a big squeeze, right? From a couple of angles.
Rosemary Barnes: Yeah, it’s interesting because it sounds so obvious when you say, we’re going to have this big industry here. It sounds obvious to say, Oh yeah we have to make all of that locally. Or as much of it locally as possible.
That’s the best thing for the nation. But it obviously, the evidence shows that it comes with trade offs in terms of how fast you can get your industry started and how expensive it is too. So yeah, I guess that’s the other side of the coin that. We don’t seem to focus on too much. It’s always just, local manufacturing is good.
But yeah, there’s trade offs.
Maya Malik: Yeah. And it’s very complex, like these projects and particularly in new markets when you’re just getting an industry going. And I think the other thing is when you’re in a situation like Taiwan and potentially Australia. It’s not like a, it’s not like a natural evolution of projects.
You’re really trying to fast forward the industrialization and condense it. And almost like before your first project is built, you’re already auctioning, something 10 gigawatts later. And you’re demanding people to price in the learning curve and the cost reduction that you haven’t actually seen yet.
And so all the suppliers have seen is this first project that they did, that they really struggled with and was super expensive. Then you ask them don’t worry. This is in 10 years time, you’re going to be loads better by then. So just give me something really cheap. And they’re like, no, we’re still.
Burning from that last time we did. And so like people don’t price in those costs reductions until they actually experience them. And you will get them and they will experience them initially, but you can’t get people to price that. in ahead of time. I feel like sometimes in these regimes, yeah, it looks great on paper.
And in theory, also, you think that’s what should happen, but also because you’re pre planning and you’re running auctions many years before stuff is actually built. Yeah you Yeah, maybe it’s a bit unrealistic, the expectations that people will forecast the reductions and be confident to sign contracts against that.
Rosemary Barnes: Yeah. What is the typical timeframe to go from, starting to think about a project to actually turning on your first turbine?
Maya Malik: I would say average is about 10 years. But it does depend on the country, but to get in the development phase, the like Australia, for instance, the critical path is actually approvals.
And then these processes, these competitions for awarding CBAD and off take. Actually also add quite a bit of time to your schedule because there’s a lot that you don’t start until you have certainty because you don’t want to make investments and then that kind of has the effect of extending your overall timeline.
I think in some kind of, actually in Taiwan it’s quite accelerated. So from when, when people were awarded their sites and tariffs. Like we were financially closing two years later, which is very fast. I think in Australia, from when you get your feasibility license, I think you’re more like five years later having a financial close and it’s another three years to construct.
Rosemary Barnes: It’s
Maya Malik: our
Rosemary Barnes: expectation. So we’ll be very lucky to see anything in this decade. I think
Maya Malik: you might get something in the early 2030s. Their target is two gigawatts by 2032. I think that’s realistic.
Rosemary Barnes: I want to try and tie this up nicely. So knowing what you know about all the different, the ways that all the different kinds of local content encouragement has happened around the world, what should Australia be aiming for?
I should we be manufacturing locally and if yes, what parts of it and how to encourage that?
Maya Malik: I think, we have the volume and I would say if we have the volume, I think the first step is to really decide how much do we want and how much can really stand behind. Seabirds, it will be, my cup of tea.
What are we willing to do to build good connections, to upgrade the harbors, to, give revenue support regimes and then combine that into a national target. You might even do a collaboration with New Zealand and say regionally. We’re going to be 40 gigawatts by 2040.
I don’t know. And then then that is a kind of anchor figure. And that figure is not, I know targets get a lot of flack because people see them as, very fluffy commitments that never get delivered. The key is to make it not just a, figure that we dreamed up, but actually something that works that is, actually supports an energy mix and Yeah, I can say with kind of commitments behind it to give investors, suppliers the confidence to say, Hey, this is actually going to happen.
And so we’re going to be ready for this. And then I think then it’s then putting in place the incentives and the infrastructure. Thing about offshore wind is the components are huge, they’re massive and transporting them inland, even short distances is really slow and difficult and risky.
So all manufacturing needs to be done by the quayside. And you’re talking now big components, you’ve got to get, your materials in, you’ve got to fabricate, you’ve got to store half built stuff somewhere, you’ve got to store fully built stuff somewhere else while they’re getting ready to be shipped offshore.
And so you need a lot of space on the key side, but also hinterland space. And, that those kind of harbors that are being developed 10 years work easily, right? So you need to be thinking about that and doing that, as soon as possible. And then there’s the things you can do on top of that like grants to give.
It’s a bit like this Policy that’s recently been announced say make something here. We’ll essentially subsidize it. You can give to land that’s happened in places like us and Taiwan, where they essentially say, Hey, we give you this, this quayside land for free. Please build something here.
You can give tax breaks. Like in the UK, the big T side development, which will now be, I think the biggest brownfield development in it is essentially a free port. No customs, no taxes very easy to operate in, export out or service, your domestic needs. Yeah, so there’s a number of things you can do to then, make it an easy decision.
But I will say, so start starting with the volumes. Is really key, and you, then you and you could focus at least initially on what can you deliver just to support the domestic market. And if you can also show, then as a hub, it’s super attractive to, use this as somewhere to export out and support, other markets in the region is a natural evolution.
I think Australia, yes, it’s it’s a it’s far. So you know, logistically it’s more expensive, but that’s also what will help it because it’s also going to cost a lot to make something somewhere else and ship it here. So actually you can have a bit of a cost advantage here making stuff because you’ve got that, that cost saving from not transporting it.
And I think Ben, despite this cost and you’ll say yes, and probably, you More expensive resources. I think Australia seen, it’s got, low interest rates. It’s got a sort of stable economy, politically very stable. So I think within the region, it’s also got a lot of things going for it that will make people comfortable, English speaking workforce, things like that.
Yeah, and I see something coming next, which is a demand for things to be made. With low emissions or no emissions, and then there’s going to be a race for not just who can manufacture the cheapest, but who can manufacture the cheapest using all green energy. And then I think a lot of energy intensive manufacturing is going to depend on how cheap your green energy is.
And Australia has such a big there’s something to exploit, when that comes and in, in some, spaces it’s already there. And I think, yeah, it will be that sort of thinking that makes it more and more attractive to do stuff here, to support an industry here.
Rosemary Barnes: Yeah. That’s a really nice optimistic way to finish.
And that’s one of my big hopes for Australia too, that one of the things that I, Constantly carry on about green manufacturing in Australia. Oh, good. It’s my rant too. It’s feels like it’s starting to, enough of us are ranting about this for enough years and now, Politicians are starting to talk about it too.
So maybe we’ll finally manage to pull it together. Okay we’ll finish up there. Thanks so much for joining us. That was definitely interesting and I learned a lot give me a lot to think about. So thank you. Thanks. Thanks. I really enjoyed it.
https://weatherguardwind.com/localizing-offshore-wind-kima-energy/
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MAGA Republican Runs in Wyoming
Meet Reid Rasner (photo at left). He’s a MAGA Republican running for congress in Wyoming–that’s a good fit.
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1) He’s openly gay, a terrible fit for Wyoming,
2) His politics appeals only to the true idiot. While it’s true that voters there are not well-educated, they’re aware and alert. They’ve seen trickle-down economics fail consistently since the days of Roland Reagan, and they’ll be very hard to convince that democratic socialism as it’s implemented around the world makes the nation’s citizens poor, and
3) I hate to judge a book by its cover, but he looks like a dullard.
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Congress Should Address the Climate Crisis
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IWTG Consulting on Pitch Bearing Cracks, Loose Root Inserts
Weather Guard Lightning Tech

IWTG Consulting on Pitch Bearing Cracks, Loose Root Inserts
Jon Zalar, founder of IWTG Consulting, joins to discuss broken blade bolts, cracked pitch bearings, loose root inserts, and early detection.
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!
Welcome to Uptime Spotlight, shining light on wind energy’s brightest innovators. This is the progress powering tomorrow
Allen Hall: Jon, welcome back to the program.
Jon Zalar: Thanks for having me.
Allen Hall: Uh, last time I saw you, we were in Melbourne- Yep … at WOMA 2026, and that was a huge event. We know we’re gonna do it again next year in March three, the 3rd through the 5th, so you’re invited back, of course- I can’t wait … if you can make it. Yeah. Yeah.
It’s gonna be, it’s gonna be a good time. A lot is happening in the blade world and in the wind turbine world more broadly. A lot of things we’re hearing right now are related to blade bolt connection, pitch bearing inserts still. A lot of that still happening in the United States. What is the current status of, uh, the blade connection issues in the US?
I,
Jon Zalar: I feel like it’s a growing [00:01:00] issue, not super, super fast, but it seems to be getting a little worse. There’s, you know, more bolts breaking at that joint. Um, pitch bearing cracks are, seem to be pretty common. There’s different solutions for it, and then, you know, the root inserts are another thing that we’ve talked about before that seem to be happening more and more, or maybe more and more people are finding them ’cause they’re looking.
Allen Hall: What are the first indications that you have a blade bolt or some sort of joint issue at the root of a blade? What can you see?
Jon Zalar: A bolt laying in the hub bouncing around. Um, you know, from like a– looking at it from, like, the sensors on the turbine, it’s really hard to tell unless it gets really bad. Uh, some of the OEMs have some analytics developed to kinda start to indicate if there is a aero change because there’s missing bolts or root inserts are coming out, and they’re using that as a way to go figure out which ones to go inspect first.
Allen Hall: Really? Yeah. You think [00:02:00] the SCADA data will give you some indication that you have a, basically a little bit of a loose blade?
Jon Zalar: Yeah. I, I, I think because the number of turbines and the number of data points you have, I think there is a pretty good analytic out there right now.
Allen Hall: Wow. All right. I think a lot of our operators have not taken advantage of that.
Is, is that just b- based on the high-speed data, SCADA data, or is it low-speed data you could see that same effect?
Jon Zalar: I believe it’s on the low-speed data as well, but I bet the high-speed data was used to kinda develop it.
Allen Hall: Wow. All right. So that’s a huge help to operators. Yeah. So what are you looking for if you’re looking through SCADA data, what would be the couple of markers there that say, “Hey, maybe we ought to go look up at the– in the hub”?
Jon Zalar: I don’t know exactly what they’re using, but they would basically look for maybe an imbalance or looking for certain components that are being overworked.
Allen Hall: Oh, sure. Okay.
Jon Zalar: Yeah.
Allen Hall: So your pitch actuator may be getting a little bit overworked. It would seem like one of the places- I think that, yeah … that would get loaded, right?
Jon Zalar: Mm-hmm.
Allen Hall: Okay. [00:03:00] And any vibration monitoring going on? Because it, it, uh, in some cases you’re– I’m hearing, like, millimeter gaps-
Jon Zalar: Correct. Yeah …
Allen Hall: between the blade and the pitch bearing.
Jon Zalar: So probably a combination of the ALC sensors, at least on a GE turbine, looking at that. But the PCH box also is looking at the tower vibration, so it could be a combination of all three.
I don’t know the exact- Okay … details, but between all of that, I think there are some analytics that kinda say, “Hey, go take a look.” And then I think there’s some other companies that have- tools that go monitor it.
Allen Hall: Mm-hmm.
Jon Zalar: Dial indicators remotely or even, you know, people going up there with dial indicators to go kind of rotate the rotor and kind of see if there is gapping between the blade and the pitch bearing.
Allen Hall: Is that a safe situation in your– from the gapping? I’ve heard this where they’ve basically took shims and they’re trying to measure this gap or some sort of dial indication. Is that a smart thing to do? Is it even reliable to do it that way? [00:04:00]
Jon Zalar: I, I, I think there’s some reliability there. And like, you know, these are really big parts, right?
So like a little bit of gap, it, it’s probably expected to a point, but growing gaps is where you should be a little more scared.
Allen Hall: So you’re– you would have to go do that quarterly, monthly, weekly? How, how often would you have to do it to see the progression? Because I’ve heard stories of, uh, a couple of weeks from nothing to hub crack to, “Oh, it took a year or more.”
Jon Zalar: I think it depends on the issue. I think for– if you’re looking at that, the bolted joint itself between the root inserts and the, uh, bolts breaking itself, I, I think they’re doing about quarterly. Now, the pitch bearings inspections are also quarterly. They’re al- they’re, they’re leveraging the drone inspections for the blades, and they’re looking at the pitch bearings to see if they’re cracked, right?
Uh, you guys are doing that too.
Allen Hall: Okay.
Jon Zalar: I think Coraly is doing a good job mitigating the risk, feels like.
Allen Hall: Wow. All right. [00:05:00] Yolanda, looking at pitch bearings, you’ve looked at a lot of drone images in your lifetime. Mm-hmm. How much can you see on drone images on pitch bearings? Can you see cracks and, or y- or do you see grease, which is a really indication that something is wrong in the bearing?
Yolanda Padron: You can see grease. You can see the cracks pretty, pretty well. Yeah. The drone images are, are really high quality. Uh, but you did mention that it’s something that you’re seeing a lot more. Is it because there’s a lot more aging fleets, or is it a problem with a lot of the new turbines that are coming online?
Jon Zalar: I, I think it’s an, I think it’s a more of a fatigue problem, so the aging of the fleet. And also, I think more people are looking at it, right? ‘Cause, like, initially the drones that were looking for blade cracks weren’t looking at pitch bearings, but then pitch bearings started cracking, so now they added that to whatever they buy off the drone companies, right?
Go look at my pitch bearings, for example.
Allen Hall: Hmm.
Jon Zalar: So I, I think it’s a problem of the more you look sometimes, the more you find.
Yolanda Padron: Hmm.
Jon Zalar: Yeah.
Allen Hall: So we [00:06:00] have root insert issues, which are being addressed by a couple of different companies- Yes … uh, uh, with somewhat similar solutions. OEM is offering one right now also.
Jon Zalar: I, I think there’s three solutions. There’s two uptower that are basically looking at ways to go fill the void between the root insert itself and the blade root. Um, and I– there’s another company that’s also more of a downtower solution where they’re actually, like, r- drilling out the root inserts and putting new ones in that are gonna last better, longer.
Allen Hall: Okay. So the drilling out is, would be CNC onsite. Correct.
Jon Zalar: Yeah.
Allen Hall: And they’re based over in Europe. But th- the drilling out is a take the blade down, set it on the ground sort of- Yeah. Right … doing really fine machining on the, on the blade itself. So that, that’s a different, completely different insert that’s going into that-
Jon Zalar: Correct
Allen Hall: new hole or- Yep … clean hole, right? So it’s a, just a, uh, totally different kind of product versus trying to inject [00:07:00] some s- sort of epoxy or resin into the, the void.
Jon Zalar: Right. Yeah. Uh, I mean, you would prefer to do it uptower. It’s gonna cost you less money.
Allen Hall: Sure.
Jon Zalar: But you wanna make sure you do it right, so I think, uh, I do foresee it being a combination of both solutions kinda going forward.
Allen Hall: Is it dependent upon, like, how much damage has been already done, or what the fatigue w- uh, an estimate on what the fatigue life is?
Jon Zalar: I think it’s strictly on measurement perspective right now. So how much gapping you have, um, kinda determines what potential solutions you have.
Allen Hall: So the gaps aren’t big, right?
So the, the gaps I hear are one millimeter is k- kind of sort of start a problem.
Jon Zalar: Mm-hmm.
Allen Hall: Three millimeters is, “I need to be making decisions.”
Jon Zalar: Yeah. So- That, that’s what I’ve heard, too. Yes.
Allen Hall: Three millimeters is about a eighth of an inch.
Jon Zalar: Mm-hmm.
Allen Hall: So it’s not a lot of m-
Jon Zalar: But you can see sunlight through it if you’re s- down there.
Allen Hall: Okay. That’s not… Well, you should see. That’s not
Jon Zalar: good either. Yeah.
Allen Hall: Right. Okay. So in a, in a three millimeter situation then, you’re doing what? [00:08:00]
Jon Zalar: You’re trying to decide if the uptower solutions are something you wanna go try, ’cause they’re still in the trial mode from my understanding or-
Allen Hall: Okay …
Jon Zalar: people are learning a lot.
So I think when you get to that point, you’re calling some of those companies to say, “Hey, I have this issue. I got a couple blades with, you know, .3. Can you guy- you guys wanna come take a look at it, see if your solutions, if you guys wanna go use it or not?” And then I think the ones that get too bad, from my understanding right now, is they’re, they’re replacing the blades.
Allen Hall: So they’re taking the whole blade down.
Jon Zalar: Yes.
Allen Hall: And what’s the thought process in that? Uh, versus drilling out the inserts and putting new inserts in. Is there just a composite degradation that’s happened around those joints that it just puts it at risk or, or you have actually aged the blade much faster than you would otherwise have done?
Jon Zalar: I, I think they aged that particular connection too much. So I, I- Wow … either between the [00:09:00] fatigue or lack of epoxy resin, w- whatever the actual root cause is for that root insert coming out, when it gets that bad, it’s like you’re not gonna be able to inject enough To make it adhere
Allen Hall: You can’t de-age it.
Jon Zalar: Correct.
Allen Hall: Right?
Jon Zalar: Yeah.
Allen Hall: Bring back the youthfulness of the blade. Wow. All right. And we have seen this worldwide. I know in the, in the States you hear about it all the time, but it, this seems to be not a US- Correct … problem.
Jon Zalar: It’s a worldwide problem, yes.
Allen Hall: Okay. So if, if it’s a worldwide problem, are there more solutions on the way?
I know you talked about three of them already.
Jon Zalar: I have not heard of any other ones except those three as of today.
Allen Hall: Wow.
Jon Zalar: There could be other people working on it. I think there should be.
Allen Hall: So, yeah. You would think so, yeah. So we’ll, I guess we’ll eventually hear about it on the podcast. Usually people with technology will contact us.
They might call,
Jon Zalar: yeah. They might call you, they might call you tomorrow.
Allen Hall: Sure, they may. So that leads to sort of a subsequent issue, which I think is getting grouped together. So the [00:10:00] hub crack, pitch bearing crack, root insert pullout issue is also discussed with blade bolts being broken.
Jon Zalar: Correct.
Allen Hall: Are they related or are they separate engineering problems?
Jon Zalar: If you look at them individually, you’d probably come up with some separate answers, but if you combine them all together, you kind of start looking at is there too much loading happening in the leading and trailing edge of the blade? ‘Cause the hub cracks, the root inserts, and the blade bolts, from my understanding, are happening at those two highly loaded areas of the, the blade or that whole rotor connection.
So I mean, I do feel the root cause is probably a little higher loads than anticipated.
Allen Hall: I think everybody’s talked about when they’ve done the injection method and the drilling method, all they’re discussing is leading edge, trailing edge.
Jon Zalar: Yes.
Allen Hall: And how– It’s a question of how many- Correct … are you gonna replace.
So th- [00:11:00] that’s, those are the two highly loaded spots on the bolted connection.
Jon Zalar: Correct.
Allen Hall: And that’s where blade bolts are also breaking or, or the bolts breaking elsewhere around the periphery?
Jon Zalar: I don’t have all the data, but what I had seen, it’s very similar areas.
Allen Hall: So if you don’t pull the insert out, you’re then loading the bolt.
Cr- Right It’s one or the other, right? Right. Yeah. So the, the, the load path is the load path, so it’s coming through the insert into the bolt. Bolt’s carrying it into the pitch bearing. Pitch bearing’s carrying it into the hub.
Jon Zalar: Correct.
Allen Hall: Hub carrying it downtower. So eventually, one of those, uh, links in the chain is- The weakest.
Yeah … is, is the le- is the weakest. What is it about blade bolts that is so dangerous? We hear– we walk onsite to an O&M building, there are signs saying, you know, “Pay attention for loose bolts. Look around on the ground for loose bolts.” We’re gonna– and as electrical engineer, like, “Whoa.” Bolts should not be falling out of this tower.
What i- what is that sort of sequence where a [00:12:00] bolt would escape from the nacelle?
Jon Zalar: So let’s just use one bolt. One bolt breaks, falls in the hub, bouncing around, doing some– potentially doing some damage inside the hub. And ’cause these turbines, you don’t need to go out there every day ’cause they do run pretty good, right?
Right. You just do your regular maintenance. And if you don’t really know about that, ’cause, like, it bounces around for a while, then it usually gets, like, lodged behind a, uh, either center box or pitch cabinet or actually in the front sometimes. Kinda don’t know it happened. But, you know, frees itself up, keeps bouncing around, it, it could escape through the hatch covers ’cause, you know, people have to get into the hub anyway.
And I’m sure a lot of people listening here that have sites, like, you know, probably found some bolts laying on the ground, which is a little scary.
Allen Hall: Right. So is, is the busting the hatch opening levers? I know there, there’s a couple different ways to get into that hatch. Yeah. But, uh, is it just completely busting the hatch?
Yeah. So it’s– [00:13:00] okay. So you see a– so if you see a loose hatch panel, you have an issue. You probably gotta be careful about coming up on that turbine?
Jon Zalar: Potentially. A lot, a lot of hatches are, you know, not always maintained well.
Allen Hall: Right. I’ve seen them, I’ve seen loose ones, yeah.
Jon Zalar: Yeah.
Allen Hall: Okay. So that, that would be a sign that– but though if, if you’re approaching a turbine, one look on the ground.
And Yolando, you, you’ve seen a lot of turbines. So are you, are we looking on the ground and seeing what’s around the turbine before we approach the turbine now? Yeah. Just, just a sanity check?
Yolanda Padron: Yeah. Be aware also of what’s happening on site, right? Because if it’s some- if it’s a problem on site, you need to be extra careful when you’re approaching any turbine there.
Uh, is it something that people maybe should start thinking about implementing, like, a sensors earlier on than when they’re seeing the issue actually happen?
Jon Zalar: Yeah. I, I, I think that’s a potential, ’cause it, the quicker you catch it, the less damage you’re gonna do, and it also reduce the risk of [00:14:00] it, um, falling out of the hub And I’ve worked with a couple of my, uh, customers for some, like, potential ways to detect it.
Still kind of trialing it right now. But I, I do think there’s gonna be some benefit from a safety reduction, but also from a strictly a damage. ‘Cause, like, you get a couple bolts bouncing around there, and you bang up some cabinets or some pitch motors, that’s expensive and hard to go fix.
Yolanda Padron: Yeah, we were talking about it earlier too.
Like, it goes down, it can hit a transformer, it can hit, like, a truck or someone.
Jon Zalar: Chance of it hitting someone. Yeah. I mean, I don’t care what hard hat you have on, it’s not gonna do anything.
Yolanda Padron: Yeah.
Allen Hall: So what kind of sensor should you be putting onto the turbine if you don’t have access to the SCADA data or you don’t know what the correct algorithm is to suss out there’s something wrong up there?
But a, a bolt breaking is not gonna be something that a SCADA would even pick up, I don’t think. One bolt out of the whole- Yeah. No.
Jon Zalar: No way. Okay. I mean, there’s a– I think there’s, like, [00:15:00]one company looking at more of a, like, mechanical way to, like, prevent the bolt from coming out. I forgot the name of it.
Allen Hall: Okay.
Jon Zalar: Um, and then what I was looking at was more of a, like, you know, microphone type detection to kind of listen for that.
Allen Hall: It would make a lot of noise.
Jon Zalar: Yeah. It seems like it works. It, um, yeah, still more development needed on my end.
Allen Hall: So- The engineer in me was, is saying, “Why are we not putting strain gauges on bolts?”
I picked on the leading and the trailing. It’s like right dead center there to look at, even if it’s just two strain gauge bolts to see what the loads are.
Jon Zalar: So like there are s- there are bolts that are, or that are made with the strain gauges built in that you can use to go, you know, monitor that. But you also need to understand like what was the design intent.
So unless you’re working with the OEM, you don’t really know what you’re seeing is good or bad. You just say, “Oh-
Allen Hall: You just see a number.
Jon Zalar: Yeah. Right. I mean like, and if you install, I don’t know, four, you’d be like, “All right. Leading and trailing edge are higher [00:16:00] than the other two.” Well, yeah, it’s supposed to be, but like is a 10% difference expected or not expected?
Allen Hall: Is that something where if you’re, especially if you’re in a full service agreement, and a lot of these turbines are- Yeah … for the first couple of years, if you were to do that, it’s something you would just say to the OEM, “Hey, this is, these are the loads we’re seeing from the strain gauges on these bolts.
Does this make sense to you?” Or, or would an OEM just not even respond to that kind of inquiry?
Jon Zalar: I mean, I think it’s all about relationship with the OEM. I, I, I think
Allen Hall: it- I think they would wanna know.
Jon Zalar: I have a feeling they probably are looking.
Allen Hall: Okay.
Jon Zalar: I mean, ’cause I mean they have the test turbines too that they probab- that, that I know they have instrumented heavily.
Allen Hall: Yeah. So they, they’re probably getting at least some feedback. Th- that’s the problem. Yeah. And you worked on the other side, right? I have. So you worked for an OEM doing the RTAs. The first problem is you don’t have data, so now you gotta go get the data.
Jon Zalar: Correct.
Allen Hall: And that data is not available tomorrow. No.
‘Cause you’re gonna have to go run some sort of design of experiment to go figure out if [00:17:00] there is even a true problem or even what the root causes could be.
Jon Zalar: And it, and it’s expensive to go instrument a blade and get the data back at the right speed and connected to the turbine data. I mean, I rem- I, I used to say it’s about like 300 to 500,000 to go put a couple gauges on a blade just with all the equipment you need to get the data correct.
Allen Hall: To get the right data.
Jon Zalar: Get the right data at the right frequency connected to the controller. It’s, it’s very expensive.
Allen Hall: Wow. Okay. Yeah. I, I don’t, I don’t see a lot of operators doing that.
Jon Zalar: And especially connecting it to the operating data, right? So like if you go put a strain gauge and I don’t know, you’re curtailed, you’re only making, I don’t know, a megawatt- Doesn’t matter.
And if you don’t know what the turbine’s doing and you’re looking at this, like, strain gauge data, it’s really hard to correlate anything.
Allen Hall: So you need a full suite of data. Yeah. That includes weather data- Yeah … at some level, right? Gust winds and- Oh,
Jon Zalar: yeah …
Allen Hall: average wind speed. You need the anemometer. You need which, which way [00:18:00] the n- cell’s pointing.
Y- uh, you would need a lot of information- And what the controller’s- … to even suss it out …
Jon Zalar: and what the controller’s doing, right? Right. ‘Cause, like, every turbine, the controller’s trying to, like, you know, balance the rotor the whole time. It’s trying to, you know, micro pitch depending on what the winds are doing.
And if you don’t know what all that stuff’s doing, like, it’s really hard to correlate a strain gauge measurement to is that bad or not.
Allen Hall: It’s a complicated problem.
Jon Zalar: Yes. That’s why RCAs take, you know, a long time, and they’re not done in two weeks.
Allen Hall: No, they’re done in a year.
Jon Zalar: Yeah.
Allen Hall: Typically, or longer. So what should an operator be thinking about now?
If, if we s- get our drone images back, we’re scanning through them like, “Oh, there’s a crack” What am I doing next besides calling you and connecting to your LinkedIn page?
Jon Zalar: So right now with the pitch bearing crack, um, some of the OEMs are providing stiffener plates to put over the crack and try to run it.
Allen Hall: So that’s a doubler plate, basically. A double plate. Doubler
Jon Zalar: plate, yes. [00:19:00]
Allen Hall: Yeah. Okay. So even in a, in a crack scenario, that pitch bearing, if given mechanical support, can run like that?
Jon Zalar: That’s my understanding, yes. That, that potentially could run for some period of time. I don’t know if it’ll make it 20 years or not, but it’ll buy you time for sure.
Allen Hall: Does that involve a crane to do that work or is that just… My recollection, that was in pieces, like there, it’s not a ring, it’s a, a couple of pieces that you’d be able to bolt on without taking the-
Jon Zalar: No, it’s a- … blade down … it’s a, it’s a single piece that-
Allen Hall: It’s like a single casting kind of thing.
Jon Zalar: Right. And I, I think you need some like small crane, like a jig crane or one of those-
Allen Hall: Just to support the blade while you do it?
Jon Zalar: And to go put it in, right. Okay. Yeah, I don’t think, you’re not taking the blade off. You’re not taking the
Allen Hall: blade down.
Jon Zalar: Correct. Yeah. It’s, it’s done with the blade up there.
Allen Hall: Okay.
Jon Zalar: You’re putting new, putting longer studs in and putting the plate on.
Allen Hall: So first step is let’s get the joint reinforced. Right.
That’s the easy first step.
Jon Zalar: Right. Although there has been some cases where since [00:20:00]you’ve put that stiffener plate on, the loads get spread out to the end of the plate, and then you- Sure … you could see cracks there.
Allen Hall: Okay. All right. So the loads- It, that- … have to go somewhere …
Jon Zalar: loads have to go somewhere. That’s, that is a bottom line.
Allen Hall: All right. So you’re just changing where the load path is, so you have to be cognizant of that. Okay. Sure. Fine. But if you have, uh, especially in the United States, you don’t have 10 of these turbines, you have 50, 100- 100 … 200, 300 of these things, or thousands as it, as it turns out. Are there simple solutions that can be applied to, just to give me a sense, like that turbine’s having a problem, but the one next to it’s not, and, and just, just from a maintenance spin standpoint where I’m not just blanketing everything and trying to do everything to all these turbines at once, how do I, how do I manage this?
Jon Zalar: I, I think it’s like being very observant. So like, you know, making sure you’re looking at the pitch bearings from the drone images, right? Um, also talking [00:21:00] to your maintenance people like, “Hey, are, are you finding a bunch of broken bolts? Like, what positions?” Like, you know, if I was back at the OEM, I would like to have as much data as possible on this issue.
Like how many bolts are, when did you find them, what positions? A lot of times we, when I was there, like we would not get all that information, so it’s like really hard to run an RCA without that information.
Allen Hall: Sure. Yeah, where did this bolt break in the ring?
Jon Zalar: Right.
Allen Hall: Could tell you a lot. Is it just a b- bad lot of bolts, or is it something more load related?
Jon Zalar: Correct.
Allen Hall: Wow. Okay.
Yolanda Padron: Yeah, I think that’s a really good point, too, to make sure that you’re connected with like every stage of the operations. ‘Cause I know that everybody’s obviously really, really busy on a wind farm, but it’s really common for like an engineer to have certain data and the site team to just be running around and having a lot of data, but maybe they don’t realize that, oh, it’s important to know how many bolts per tower are coming down.
Jon Zalar: Correct. Yeah
Allen Hall: That’s a lot of work
Jon Zalar: It definitely-
Allen Hall: It’s a tremendous effort if you’re gonna [00:22:00] go after this problem and, and solve it RCS
Jon Zalar: are hard. They
Allen Hall: are. Yeah. All of it. Yeah. Machines are complicated today. There’s a lot of computer-driven s- things about them, and then you have these loading issues, and you have composite materials.
Th- there’s just, y-
Jon Zalar: you got to get- It’s a very complex
Allen Hall: It’s a machine, right? Yeah. It’s a complex machine. So how do people reach out to… You’re, you’re the head of IWTG, which is based in South Carolina, but you do consulting worldwide. Yes. And, and you are a huge resource because you understand the complexities of these problems.
How do people get ahold of you and, and get something started if they have a, a, a blade bolt issue or an insert issue or a cracked pitch bearing? Where do they start?
Jon Zalar: They can send me an email, jzalar@iwtgconsulting.com.
Allen Hall: Okay. And you have a great LinkedIn page, so you can connect with you on LinkedIn.
Jon Zalar: Yes.
Yeah, I have one
Allen Hall: of those. Yes. Or you could just come to WOMA in [00:23:00]2027. Yeah. You can. You can meet John there and, and arrange everything there. So John, it’s great to see you, and thank you for coming up. We, uh, we’re recording this at the world headquarters of Weather Guard Lightning Tech, and, uh, John just lives down the street in, in, in US terms.
Yeah. So it’s, it’s great to have John come and visit us up here in North Carolina. So John, thank you so much for joining us.
Jon Zalar: Thanks for having me. Appreciate it.
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