MotorDoc’s Electrical Signature Turbine Diagnosis
Howard Penrose from MotorDoc discusses their electrical signature monitoring for wind turbines that offers precise diagnostics, enabling cost-effective preventative maintenance and lifetime extension.
Sign up now for Uptime Tech News, our weekly email update on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on Facebook, YouTube, Twitter, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary Barnes’ YouTube channel here. Have a question we can answer on the show? Email us!
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Allen Hall: Howard, welcome back to the show. Thank you. Well, we’ve been traveling a, a good deal and talking to a lot of operators in the United States and in Europe, and even in Australia. And, uh, your name comes up quite a bit because we talk to all the technical people in the world and we see a lot of things. And I get asked quite a bit, what is the coolest technology that I don’t know about?
And I say, Howard Penrose MotorDoc. And they say, who? And I say, well, wait a minute. If you want something super powerful to learn about your turbine, that is easy to implement and has been vetted and has years of in-service testing and verification. It is MotorDock, it is [00:01:00] empower for motors, it is empath for systems and vibration and all the other things.
And now empath, CMS, which is a continuous monitoring system that you’re offering that those systems are revolutionary and I don’t use that word a lot in wind. It’s revolutionary in wind and. Let, let me just back up a little bit because I, I want to explain what some of these problems are that we’re seeing in the field and, and what your systems do.
But there’s a, the, the core to what your technology is, is that you’re using the air gap between the rotor and the stator and the generator to monitor what’s happening inside the turbine. Very precisely. Can you just provide a little insight like how that magic happens?
Howard Penrose: Okay. It’s, it’s basically, we use it as an, as a basic accelerometer.
So, um, the side to side movement of the, of the rotor inside the air gap. Um. I could get very technical and use the word [00:02:00] inverse square law, but basically in the magnetic field I’ve got side to side movement. Plus every defect in the powertrain, um, causes either blips or hesitations in the rotation.
Basically, the torque of the machine, which is also picked up in the air gap, and from a physics standpoint. The air gap, the magnetic field, can’t tell the difference. And, um, both voltage and current see that as small ripples in the wave form, and then we just pull that data out. So, um, uh, I, I liken it exactly as vibration.
Just a different approach,
Allen Hall: right? And that that vibration turns into little ripples. And then I’m gonna talk electrical engineering, just for a brief moment, everybody. We’re taking it from the time domain to the frequency domain. We’re doing a four a transform. And in that four a transform, you can see these spikes that occur at, uh, known locations that correlate back to what the machine is doing
Howard Penrose: exactly.
[00:03:00] They’re they’re exact calculations, uh, down to the hundred or even thousandths of a hertz. Uh, so, uh, when we, when we do the measurements, they come up as side bands around, uh, whatever. The, the, uh, signature is, so the amplitude modulation, it’s an amplitude modulated signal. So I have, uh, basically the ripple show up on the positive side of the waveform and on the negative side of the waveform.
So around everything, I just have plus and minus line frequency. That’s, that’s basically the primary difference. Then we just convert it over to decibels, which makes it, um, relational to the load, which means load doesn’t matter. Uh, so I can compare an unloaded machine to a fully loaded machine and get the same results,
Allen Hall: which is also amazing.
So the load, what the turbine is doing doesn’t really matter at all, as long as it’s rotating and producing power. You can [00:04:00] monitor what’s happening, sort of anything up, and then the cell. Mostly,
Howard Penrose: well, it’s even, it’s even more fun than that because the air gap in a wind turbine is at a fixed speed for a dfi.
So, uh, it’s constantly turning at the exact same speed, which is basically all I need regardless of the physical speed. So, vibration, I need to know that physical speed and electrical signature. I need to know the air gap. Speed.
Allen Hall: So with this data and the way you’re monitoring what’s happening on the turbine is through current sensors on the feeds and voltage probes.
You could do one or the other and, and you’ve done both, and we can discuss that for a moment. But just using the what’s happening on the wires, on the generator wires, now he can determine everything that’s generally happening mechanically. So from gearbox to the blades. The, [00:05:00] the hub, uh, you can even determine things that are happening up tower a little bit like ya motors and that sort of thing.
If they’re acting weird, you can see changes there. And it’s sort of like the pulse of the turbine
Howard Penrose: and the main bearings. And the main bearings, right? So all the bearings never leave out the main bearings. That’s, that’s a study we’re involved in right now. So, um. Yeah. Uh, oh. Yeah. The, the study right now is, uh, we’re using the technology to map out circulating current sub tower.
Um, so we’re, we’re looking at, uh, why main bearings are failing, um, which was missed before. I’ve got an, I’ve got a paper coming out on it. We’re kicking off an NRE L study, uh, on it. And we are also working along with, um, groups in the field and an independent study all to. Well, a main bearing is a really expensive issue.
Um, and, and we’re fine. People are just [00:06:00] finally figured out that they were failing because of electrical discharge. And, um, the high frequencies associated with that basically caused the brushes to become resistors and the bearings to become conductors. So, uh, we now have a technology that allows us to look at these very high frequency sound or.
High frequency
Allen Hall: noise. Okay. Let’s just use that as a test case for your system for iPath CMS, because. That is one issue that pretty much everybody in the United States that uses a particular OEM has
Howard Penrose: actually, uh, you, you got, you hit it on the head. It’s just like the old W Ring thing. Everybody thought it was a specific, uh, generator manufacturer turned out to be every DFI failing the same way we discovered that.
Uh, we’ve also heard, uh, you know, a specific OEM and a specific. Type of platform. They were seeing the problems in the main bearings. And again, it just came about because people were talking about it. Except [00:07:00] guess what? We’re not just seeing it in the us, we’re seeing it globally. That’s one of the benefits we have with so many users worldwide is we’re finding out that all of these problems are not unique to us.
They’re global in nature and they’re cross platform.
Joel Saxum: So when we talk cross platforms and, and you, the listeners here will notice that I’ve been markedly absent from the conversation so far. ’cause it’s a bit over my head. Sorry. No, it’s, it’s just, this is, this is great stuff. But what I, that was one of the things I was wondering while we were going through this is we were talking about, um.
Solutions that you guys have that can solve specific problems. Now, does this say I have a direct drive turbine? Or like, is, is there any models or any types of technology that you can’t work on out in the field or does it Basically we have a solutions that can cover all turbines regardless
Howard Penrose: if it’s got a magnetic field, whether it’s a generator, motor, or transformer, we can see it.
I can follow that. So we even, we even, we even use [00:08:00] the technology in the industrial side for power monitoring for plants. Because we get, uh, we get good insights on what’s coming into the facility and what the facility’s putting back into the system, in particular with high frequency noise and stuff like that, that utilities are just now starting to pay attention to.
Joel Saxum: It’s just, this is an important thing for the CMS system that you guys have, because I’m, I’m thinking right now, okay, now, now again, I’m gonna dumb this way down, um, in my. Built Jeeps that I’ve done in the past, I’ve gotten death wobble in the steering wheel because of oscillations in the front axle.
Right? But that only happens at a certain speed, right? If I, if I could, if I could get through second gear at about 4,000 RPMs and grab third, I’m fine. But if I have to shift to 2,500 RPMs, about 32 miles an hour, I’m in a world of hurt, right? I’m, I’m shaking this thing down the road. So turbines I know will do that sometimes at certain RPM.
They will have vibration issues that will either go away or expand a resonance or natural [00:09:00] frequency.
Howard Penrose: Yeah,
Joel Saxum: right. Like at, at at, um, you know, four RPM is one thing at seven and a half rpm it goes away. So having cm, your CMS system, that’s their continuously monitoring when the wind speeds are low, when they’re high, when.
Does that help you pick up different anomalies within the turbine to be able to kind of pinpoint what’s, what could be happening?
Howard Penrose: No, because those frequencies are always present. They just amplify at certain points in speed, right? They, they hit a natural frequency, so they just oscillate like mad. Uh, I’m rereading all of my Tesla books right now.
So where, where he talks about that, you know, you could split the world like an apple if, if you hit the right frequency. Um. With a small device. Uh, so, uh, yeah, we see it across that entire speed range, even though you feel that oscillation. One of the nice things about, um, uh, electrical and current signature is it isn’t a structural vibration analysis.
Like if, if I [00:10:00] have the, um, structure or the machine vibrating outside, I see very little of that. I see all the drivers behind it instead. Right. So it, it’s, it’s less likely, uh, I’ll pick up a false positive because I hit a resonance. That amplitude remains the same.
Joel Saxum: That’s the difference between what you guys are doing and what and what everybody else is doing with a accelerometer, gy, gyro, whatever that sensor may be.
You name it,
Howard Penrose: accelerometer, ultrasound, all that other stuff. It’s all variations of,
Joel Saxum: of physical.
Howard Penrose: Yeah, and I refer to those as basically fault detectors. They’re dummy lights. Nobody’s actually using condition-based maintenance as condition-based maintenance. We can use the information to actually make modifications and changes.
Joel Saxum: You can actually diagnose with yours. That’s what we always say right now. CMS basically at, at this, at a general level is go and look at this turbine, bing. Go and [00:11:00] look at this turbine. You have a problem. Go and look. One of these blades has a problem. Go and look at it. But you are actually going deeper down saying diagnosis, Hey, this may be the actual problem that’s causing.
This issue in your turbine, and that is invaluable.
Howard Penrose: Yeah. One of our case studies is of a bearing a man, a a a a re, a reinstalled bearing on a, or an installed bearing on a drive end of a a wind turbine. The, um, it had some problems with, uh, the cage, which caused one of the roll balls not to rotate. Um, and it had some false brunel on in the inner outer race, and we saw that, but we also saw, uh, a much higher level in the thrust bearing in the gear box.
And so when we, we went back to them and said, yeah, you’ve got a problem here. Uh, they took the bearing back off, and then I said, make sure that you’ve got all the shims in the. And the, uh, coupling and they had left out a shem, so it had [00:12:00] caused a problem in the, so if we hadn’t detected the other thing, we would’ve detected the gearbox, um, bearing.
But they were ignoring that data and were looking at the bearing. They just replaced in the generator. So when, when they put everything back together, we were able to confirm that. All we saw after that was the friction losses in the, in the bearings.
My
Joel Saxum: question is, is okay, we’re looking at. Basically deltas outside of a, a sine wave and these peaks and valleys to in your, in the sign you’re detecting, how are you able to know, oh, I saw this delta here, or I saw this here.
That’s a thrust bearing. That’s a main bearing. That’s something here. Is that just years of knowledge built up from, okay, we saw this fault and we, we figured it was this because of it, or. How are you guys arriving at that?
Howard Penrose: Uh, it’s from my years as a, uh, vibration analyst, um, Navy trained vibration analyst.
Uh, [00:13:00] so, um, what, what was discovered by Oak Ridge National Labs in the 1980s? So this isn’t that new. As a matter of fact, this technology is direct descendant from Howard Haynes’s work another Howard. What we discovered was the frequencies are. For the most part, exactly the same as what we look for in vibration, just side bands, right?
Because we, we, you know, I tell people, how do you interpret the data versus vibration? Stand on your head and cross your eyes. Um, being former Navy, I sometimes use some other, you know, things such as go out and drink heavily. Uh, but in any case, um. Instead of looking from bottom up, we’re actually setting whatever the peak line frequency, current or voltage is, that’s zero.
And then we, uh, relate every other peak, um, based upon 20 times the log 10 of the difference in the current, from the current in [00:14:00] question back to that peak. Which is kind of cool because that also means that it’s. As my load changes, everything follows. So it’s not load dependent. The only thing that happens is frequency.
So you have to take enough of a, a data across a long enough time so that you can determine the differences between the, the components, right? So, so in a wind turbine for instance, I’ll have all those bearings in the gearbox, including the planetary gears. I have the main bearing, and they all kind of crowd around line frequency.
I need a resolution that’ll show me a hundredth of a hertz difference between any two peaks. It’s it’s vibration. It’s actually vibration. So the, each of the components, even each component of the bearing, ’cause I can call out which part of a bearing, and that’s actually how we analyze what conditions we’re looking at.
If it’s, uh, cage and ball only, and no signature off of the inner and outer [00:15:00] race, chances are it’s lubrication. Um, you know, that kind of thing on a main bearing. If I see the outer race cha and nothing else, chances are, uh, they didn’t clean out all the old grease and there’s dried grease across the bottom.
Uh, we discovered that actually with a couple of the, a couple of sites. So we, we say check, check greasing and condition of the inner and outer rays, you know, that kind of thing. And, uh, we’ve been right more than wrong. Uh, the, the quoted, the quoted number back from one of the OEMs is about 95% accuracy.
And when you consider, when you consider borescope has been identified at less than 50%, um, it, it, it gives you a really high accuracy.
Joel Saxum: We just had a conversation with someone the other day, Alan, you and I, about borescopes and how can you borescope so think that’s full of grease And they were like, oh, yeah.
Allen Hall: Yeah, it’s difficult.
At best. Well, and that’s the power of [00:16:00] what Modoc is doing, and what Howard’s doing is that it can detect a range of problems early. And as we get into this area of where o and m budgets are becoming restricted, and you need to spend your money wisely. Do preventative maintenance, which is what MotorDoc is all about, is catching these things early before they become really expensive.
Electrical signal analysis is a very simple way to get that data, which is what the Empower Empath and then Empath CMS system are doing is they’re, they’re reading those electrical signatures and correlating back to where the problem is and the success rate is. Howard, as you pointed out, is. Really high, uh, a lot of systems that I see and I was just went to Europe and looked at some data on some other systems, it’s about 50 50.
Well, if 50 50, I could flip a coin at that point. It’s not of any use to me. It has to be somewhere north of 90 where I become interested. And your system, when I talked to operators that use it, [00:17:00] said, well, geez, um, you know, it’s well in the high, in the nine high nineties all the time and it’s amazing what they can pull out.
It’s this bearing or that bearing or this problem with this motor or this problem with the system and the amount of money they’re saving to pick up those problems early and to get them repaired when it’s lower cost or to keep an eye on ’em even, which is an option, lowers our operational budgets down and it makes sense.
So the, the cost of a CMS system is only relative to the money it saves. And I think this is where a lot of operators are getting a little hung up. There’s a lot of CMS systems, which are you pay per year for, and it’s a constant expanse. It adds up to the om OMS budget and no one wants to do that. What you’re seeing now with MotorDock is that system is a capital expenditure.
You buy it, it comes with the hardware, it comes with the [00:18:00] software, it comes with all the knowledge and all the updates I think are free. So. It makes a lot more sense to use a MotorDoc type of system and empath CMS than necessarily to, to put individual CMS systems on that maybe do less than what Howard can do.
Joel Saxum: I think an important thing here too, Alan, is as we get to, uh, an era of lifetime extension, I. People looking for that solution. How do I guarantee the safety of my turbine, the operation of my turbine as we continue to roll this thing forward? I know here, even in the states, we always say PTC, 10 year repower.
That’s not the case for all these turbines. We have 80 20 repowers. We have a lot of ’em. Like, Hey, we have a good PPA. So these things have been, these are 14 years old, we’re still gonna run ’em. We’re not repowering these, or in Europe or in other places in the world where we don’t have the same kind of tax setup we do, where they’re trying to squeeze as much life outta these in, you know, originally 20 to 25 year lifetimes.
Man, if you can put something on there that can tell you you’re good to go, or Hey, you need to watch this, or This is the next big spend you have coming up, they can help those operators to make decisions [00:19:00] to for lifetime extension in a really, really good way.
Allen Hall: Going into the data acquisition system and how it connects to the turbine, I know it’s one of the problems that we run into occasionally, is using anything that the the Tower has in terms of data streams.
They want of a lot of it information. Does your system plug into the data system of the turbine or is it independent, or how does that work and what is the security features?
Howard Penrose: Yeah, whatever they want. So, uh, that, that, and, and you bring up a good point, like wireless is not allowed. Um, but everybody’s using it, right?
Um, there’s a lot of things that aren’t allowed that we were, we were. Privy to during NIST’s work and, and others’ work on cybersecurity on the hill, because I was advising that stuff back in the, you know, back, uh, prior to 2020 and a little bit afterwards. Um, so, uh, uh, [00:20:00] yeah, we, our system was originally designed for nuclear power plants.
So, uh, it’s meant to either. It’s a wired system basically, that you can take back to an independent server. You can have it go locally and send it through your own, uh, own network. Um, it doesn’t need to connect to cloud or somewhere else. Uh, if you want to keep it itself contained. Uh, in some turbines we have gone the route of, uh, cellular modems.
For, for each of the towers. Um, you know, when, when they’re permanently installed, a lot of people just do data collection. I mean, when you consider, like in a GE turbine, um, if I go, if I personally go to a site and I’ve done over 6,000 turbines in the, in the US and Canada myself, um. And if you could see me, you know, I don’t climb.
[00:21:00] Um, yeah, that’s my running joke. It’s like, yeah, I don’t think the ladders will support me. Uh, but any case, um, the, uh, normally it’s walking the base of the tower gathering data as long as the transformer’s down tower and moving on to the next one, I, I think my record is seven minutes a tower, including traveling in between.
So it’s not unusual to knock out a single data collection on a site within, uh, if it’s 120 turbines, normally three days. Three and a half. If there’s a, if it’s summer and they’ve got that wind break in Texas where, you know, it’s changing direction, so it takes a lunch break.
Joel Saxum: You’re a small company, right?
Just like we are here at Weather Guard where we’re flexible to what the client wants. So if the client wants a certain thing, we can deliver a certain thing. If the client needs this, they can, we can do this. So you get, you guys can do the, the CMS UPT Tower where it’s like you have an installation and it’s gonna be there.
Or hey, we can just come to your site, boom, boom, boom, do some testing, and be outta there and give you some reports like you can, you [00:22:00] have a lot of solutions that you can help people out with.
Howard Penrose: We even have, uh, most of the, um, uh, wind service companies, you know, motor repair shops and generator repair shops and everything else have our technology.
They also provide the service. Uh, that’s our model is the more the end users or service companies can do it, the better. Uh, we, we made the choice not to, you know, I don’t want a room full of people that are sitting there doing nothing but analysis, right? They’re gonna burn out. Uh, I’d rather be doing the research and identifying the problems, finding industry related issues to solve.
And our technology was built simple enough that we don’t have to handle a lot of tech support calls. Um, and, uh, and monitoring is an option. Meaning we’ll do the monitoring. I’ve got, I’ve got a number of industrial sites, some wind sites, some other energy sites. Uh, [00:23:00] all, all using the technology and getting us data, but yeah, exactly.
Smaller company. It’s broad, but the technology is not backed by just us. It’s backed by a small $12 billion company called ome. So, uh, yeah, so, and that’s not, it’s not an investor anything. It’s, they, um, they got the license from Oak Ridge back in 1991 or two and, uh, and they maintain it. And during some 97 on, uh, I, in different roles.
Uh, have been supporting the development of the technology. So we have a mutual agreement. They focus on, um, nuclear power, and I focus on everything else.
Allen Hall: Howard, we love having you on the program because your technology is just amazing and people need to get a hold of MotorDoc. So if you’re an operator, a developer, an OEM, and Wind, if you’re making some of the components for wind [00:24:00] turbines, you need to be talking to Howard and MotorDoc to get this diagnostic tool into your toolbox and save the the world a lot of money on downtime and repairs.
Howard, how do people get a hold of MotorDoc? Where do they find you on the web?
Howard Penrose: Well, we could be reached online, uh, through, uh, LinkedIn at, uh, LinkedIn slash in slash MotorDoc, or, uh, at our websites MotorDoc.com or MotorDoc ai.io. Uh, or you can also reach us via email at info@motordoc.com.
Allen Hall: Howard, thanks for coming on.
We’re gonna have you back on soon and everybody keep watching Howard on LinkedIn if you wanna find out what’s happening as MotorDoc develops more technology, watch Howard on LinkedIn. Howard, thank you so much for being on the program. Love having you.
Howard Penrose: It has been a pleasure as always. And we’ll see you the next time [00:25:00] around.
https://weatherguardwind.com/motordoc-electrical-diagnosis/
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Vineyard Wind’s $69.50 PPA, Two Offshore Lease Exits
Rosemary reports back on her visit to multiple Chinese renewable energy companies, Vineyard Wind activates a $69.50/MWh PPA with Massachusetts utilities, and Bronze Age jewelry halts a German wind project.
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!
[00:00:00] The Uptime Wind Energy Podcast brought to you by Strike Tape protecting thousands of wind turbines from lightning damage worldwide. Visit strike tape.com and now your hosts.
Allen Hall 2025: Welcome to the Uptime Wind Energy Podcast. I’m your host, Allen Hall. I’m here with Yolanda Padron in Austin, Texas, who is back from the massive wedding event. Everybody’s super happy about that, and Rosemary Barnes had her own adventures. She just got back from China and Rosemary. You visited a a lot of different places inside of China.
Saw some cool factories. What all happened?
Rosemary Barnes: Yeah, it was really cool. I went over for an influencer event. So if you are maybe, you know, in the middle of your career, not, not particularly attractive or anything you might have thought influencer was ruled out for you as a career. No one, no one needs engineering influencers in their [00:01:00] forties.
It’s incorrect. It turns out that’s, that’s where, that’s where I, I found myself. It was pretty cool. I, I did get the red carpet rolled out for me. Many gifts. I had to buy a second bag to bring home the gifts, and when I say I had to buy a second bag, I had to mention. Oh, I have so many gifts, I’m gonna need another bag.
And then there was a new bag presented to me about half an hour later. But, so yeah, what did I do? I got to, um, as I was over there for a Sun Grow event. Huge, huge event. They, um, it’s for, it’s for their staff a lot, but it’s also, they also bring over partners. They also bring over international experts to talk about topics that are relevant to them.
Yeah. They gave everybody factory tours in, um, yeah, in, in shifts. Um, I got to see a module assembly factory, so where they take cells, which are like, I don’t know, the size of a small cereal box, um, and assemble them into a whole module. Then the warehouse, warehouse was [00:02:00] gigantic. It, um, was, yeah, 1.8 gigawatt hours worth of cells that couldn’t hold in that one building.
They’re totally obsessed with fire safety there in everything related to batterie, like in the design of the product, but also in, in the warehouse. And they do, yeah, fire drills all the, all the time. Some of them quite big and impressive. Um, I saw inverter manufacturing facility that was really cool.
Heaps of robots. Sw incredibly fast. Saw a test facility.
Allen Hall 2025: So was most of the manufacturing, robotics, or humans?
Rosemary Barnes: Yeah. So at the factory it was like anything that needed to be done really fast or with really good quality was done by robots. So they had, um, you know, pick and place machines putting in. Um, you know, components in the circuit board, like just insane, insane rate.
I’m sure it’s quite, quite normal, but, um, just very fast. Everything lined up in a row. Most of their quality control is done by robots. Um, so it does well it’s done by ai, I should say. [00:03:00] Taking photos of, of things and then, um, AI’s interpreting that. Repairs, I think were done by humans. There were humans doing, um, like custom components as well.
Like not every product is exactly the same. So the custom stuff was done by humans.
Allen H: So that’s the Sun Grove facility, right? You, but you went to a couple of different places within China?
Rosemary Barnes: Yeah, I went to another, a factory, a solar panel, a factory, um, from Longie. That was really cool too. I got to see a bit more probably of the, um, interesting, interesting stuff there, like, uh, a bit more.
Um, yeah, I don’t, I dunno, processes that aren’t, aren’t so obvious. Not just assembly, but um, you know, like printing on, um, bus bars and, you know, all of the different connections and yeah, it was a bit, a bit more to it in what I saw. Um, so that was, but it, it’s the same, you know, as humans are only involved when it’s a little bit out of the.
Norm or, um, where they’re doing repairs, actual actually re [00:04:00]repairing. You know, the robots or the AI is identifying which components don’t meet the standard and then they’ll go somewhere where a human will come and, um, fix them.
Allen H: Being the engineer there. Did you notice where the robots are made? Was everything made in China that was inside the factory or were they bringing in outside?
Technology.
Rosemary Barnes: I didn’t think to look for that, but I would assume that it was Chinese made, also
Allen H: all built in country
Rosemary Barnes: 20 years ago that wouldn’t have been the case, but I think that China has had a long, a long time to, to learn that. Again, it’s not like, it’s not, it’s not rocket science. These are, these are pick and place machines, you know, like I remember working on a project very early in my career, so.
Literally 20 years ago, um, I was working with pick and place machines. It’s the same, it’s the same thing. Um, some of them are bigger ’cause they’re, you know, hauling whole, um, battery packs around. It’s just the, um, the way that it’s set up, but then also the scale that they can achieve. You just, you can’t make things that cheap if you don’t have the [00:05:00] scale to utilize everything.
A hundred percent. Like I said, wind turbine towers is a really good example. ’cause anyone, any steel fabricating
Allen H: shop
Rosemary Barnes: could make a wind turbine tower. Right? They, they could, they could do that. You know, the Chinese, um, wind turbine tower factories have the exact right machine. They don’t have a welder that they also use for welding bits of bridges or whatever.
Uh, they have the one that does the exact kind of world that they need, um, for the tower. They, you know, they do that precisely. Robotically, uh, exactly the same. And, you know, a, a tower section comes on, they weld it, it moves off to the next thing, and then a new one comes on. They’re not trying to move things around to then do another weld in the same machine.
You know, like they’re, um, but the exact right. Super expensive machine for the job costs a whole bunch to set up a factory. And then you need to be making multiple towers every single day out of that factory to be able to recoup on your cost. And so that is [00:06:00] the. The, um, bar that is just incredibly hard slash impossible for, um, other countries to clear.
Allen H: Can I ask you about that? Because I was watching a YouTube video about Tesla early on Tesla, where they wanted to bring in a lot of robotics to make vehicles and that they felt like that was the wrong thing to do. In fact, they, they, they kinda locked robots in and realized that this is not the right way to do it.
We need to change the whole process. It was a big deal to kind of pull those. Specialized piece of equipment, robots out and to put something else in its place in that they learned, you know, the first time, instead of deciding on a process, putting it in place and then trying to turn it on, see if it works, was to sort of gradually do it.
But don’t bolt anything down. Don’t lock it in place such that it doesn’t feel like it’s permanent. So you engineer can think about removing it if it’s not working. But it sounds like this is sort of the opposite approach of. A highly specialized [00:07:00] machine set in place permanently to produce. Infinite amounts of this particular product, does that then restrict future changes and what they can make or, I, I, how do they see that?
Did, did you talk about that? Because I think that’s one of an interesting approaches.
Rosemary Barnes: I didn’t actually get as much chances I would’ve liked to speak to engineers. Um, I was talking mostly to salespeople and installers. Um, so they know a lot, but I couldn’t, um, like in the factory tours, I was asking questions.
Um. That kind of question and, and they could answer all, all that. Um, but outside of that, and I couldn’t record in the factory obviously. Um, but I did, I did take notes, but what I would say is that they would have a separate facility where they would be working out the details of new products and new manufacturing processes and testing them out thoroughly before they went and, you know, um, installed everything correctly.
But what I do hear is that, you know, especially with solar power. Maybe to [00:08:00] batteries to a lesser extent. You, you know, you like, you have these kind of waves of technology. Um, so you know, like everyone’s making whatever certain type of solar cell and then five years later, um, there’s a new more efficient configuration and everybody’s making that.
And I know that there are a lot of factories that kind of get scrapped. Um, and the way that China’s set up their, like, you know, their economy around all this sort of thing is set up is that it’s not that, like every company doesn’t succeed. Right. They SGO was a big exception because they’ve been going since 1997, I think it was.
It was started by a professor quid his job and hired a room across the, across the road from his old university and, you know, built his first inverter and, um, you know, ’cause he, he could see that. Uh, the grid was gonna have to change to incorporate all of the solar power that was coming, which to be honest, in 1997, that was like pretty, pretty farsighted.
That was not obvious to me when I started working in solar in mid two thousands. And it was not obvious to me that this was a winner.
Allen H: Well, has sun grow evolved then quite a bit? ’cause if you’re [00:09:00] saying that they’ve minimized the cost to produce any of their products by the use of robotics, they have been through an evolutionary process.
You didn’t see any of the previous generations of. Factories. You, you were just seeing the most modern factory that that’s actually producing parts today. So is that a, is that a, is that just a cost mindset that’s going on in China? Like, we’re just gonna produce the lowest cost thing as fast as we can, or is it a market penetration approach?
What are, what were, were the engineers in management saying about that?
Rosemary Barnes: I think there’s a few different aspects to that, like within China. So Sun Grow is the big company with a long track record and they’re not making the cheapest product out of China. So I think that they are still trying to make the cheapest product, but they’re not thinking about it just in the purchase price.
Right. They’re thinking more in terms of the long, long term. You know, they’ve been around for 30 years and probably expect to be around for another 30 years. They don’t wanna be having [00:10:00] recalls of their products and you know, like having to, um. Installers in particular are probably working with them because they know that they won’t have to go back and do rework and the support is good and all that sort of thing.
So they’re spending so much money on testing and you know, just getting everything exactly right. But I don’t think that that’s the only way that China is doing it. There’s, you know, dozens, probably hundreds of companies. Um. Doing similar stuff between Yeah, like solar panels and associated stuff like inverters and, and batteries.
So many companies and all of them won’t succeed. You know, sun Girls Facility in, I was in her and it’s huge, you know, it’s like a, a medium sized country town. Just their, um, their campus there, they’re not, they’re not scrapping that and moving to a new site, you know, they’re gonna be. Rejiggering and I would expect that, you know, like everything’s set up exactly the way it needs to be, but it’s not like gigantic machines.[00:11:00]
It’s not like setting up a wind turbine blade factory where it’s hard if you designed it for 40 meter blades, you can’t suddenly start making 120 meter blades. Like it’s, they will be able to be sliding machines in and out as they need to. Um, so I, I, yeah, I guess that it’s some, some flexibility. But not at the cost of making the product correctly.
Allen H: Did you see wind turbines while you were in China?
Rosemary Barnes: I, the only winter I saw, I actually, I saw, because I caught the train from Shanghai, I actually caught the fast train from Shanghai to, which is about, it depends which one you get between like an hour 40 or three hours if it stops everywhere. Um, and I did see a couple of wind turbines on the way there, out the window, just randomly like a wind turbine in the middle of a, a town.
Um, so that was a bit, a bit interesting. But then in the plane, on the way back, the plane from Shanghai to Hong Kong, I, at the window I saw a cooling tower of some sort. So either like a, yeah, some kind of thermal [00:12:00] power plant. And then. Around all around, well, wind turbines, so onshore wind turbines. So I don’t know.
Um, yeah, I, I don’t know the story behind that, but it’s also not a particularly windy area, right? Like most of the wind in China is, um, to the west where, uh, I wasn’t
Allen H: as wind energy professionals, staying informed is crucial, and let’s face it. 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 PS win.com today. So there are two stories out of the US at the minute that really paint a picture of the industry. It was just being pulled in opposite directions. The Department of Interior announced agreements to terminate two more.
Offshore wind leases, uh, [00:13:00] Bluepoint wind and Golden State wind have agreed to walk away from their projects. Global Infrastructure Partners, which is part of BlackRock, will invest up to $765 million in a liquified natural gas facility instead of developing blue point wind. Ah. And Golden State Wind will recover approximately $120 million in lease fees after redirecting investment to oil and gas projects along the Gulf Coast, and both companies say they will not pursue further offshore wind development in the United States.
Well, we’ll see how that plays out. Right? Meanwhile. In Massachusetts Vineyard Wind, which has been fighting with GE Renova recently has activated its long awaited power purchase agreement with three utilities. The contract set a fixed electricity price of drum roll please. [00:14:00] $69 and 50 cents per megawatt hour for the first year and a two and a half percent annual increase.
Uh, state officials say the agreements will save rate payers $1.4 billion over 20 years. So $69 and 50 cents per megawatt hour is a really low PPA price for offshore wind. A lot of the New York projects that. Renegotiated we’re somewhere in the realm of 120 to $130 a megawatt hour, and there’s been a lot of discussion in Congress about the, the usefulness of offshore wind.
It’s intermittent blahdi, blahdi, blah. Uh, but the, the big driver is what costs too much. In fact, it doesn’t cost too much. And because it’s consistent, particularly in the wintertime, uh, electricity prices in Massachusetts in the surrounding area are really high. ’cause of the demand and ’cause how cold it is that this offshore wind project, vineyard wind would be a huge rate saving.
And [00:15:00] actually the math works out the math. Math everybody. Do you think this is, when we go back five years from now, look back at this. This vineyard wind project really makes sense for Massachusetts.
Yolanda Padron: I think it really makes sense for Massachusetts. I’m really interested to know what the asset managers are thinking on the vineyard wind side, um, and if they’re scared at all to take this on.
I mean, it’s great and I’m sure they can absolutely deliver. Like generation I don’t think should be an issue. Um. I just don’t know. It’s, it sounds like they’re leaving a lot of money on the table.
Allen H: I would say so, yeah. But remember, the vineyard win was one of the early, uh, agreements made when things were, this is pre Ukraine war, pre Iran conflict on a lot of other, a lot of other things.
It was pre, so I remember at the time when this was going on that. P. PA prices were higher than obviously a lot of other [00:16:00] things. Onshore solar, onshore wind, it would, offshore is always more expensive, but I don’t remember $69 popping up anywhere in any filing that I remember seeing. So even if they had said $69 five years ago, I think that would’ve still been like, wow, that’s pretty good for an offshore wind project.
And now it looks fantastic for the state of Massachusetts
Yolanda Padron: because I know that there’s sometimes, and we’ve talked about this in the past, right? There are sometimes projects where, you know, you think you, you’ve got a really good price and you’re really excited about it, and then it goes into operation and then like a couple years down the road, prices increase quite a bit and it’s not the worst thing in the world.
But you do just kind of think a little bit like, I wish I could. Renegotiate this or you know, just to get, to get our team a bit of a better deal or to get a bit more money in operations and everything.
Allen H: Does this play into Vineyard wind claiming $850 [00:17:00] million in dispute with GE Renova that at $69 PPA, there’s not a lot of profit at the end of this and need to get the money out of GE Renova right now, and maybe why GE Renova wants to get out of this because they realize.
The conflict that is coming that they need to separate the, the themselves from this project. It’s, it’s very, as an asset manager, Yoland, as you have done this in the past, would you be concerned about the viability of the project going forward, or is all the upfront costs. Pretty much done in that operationally year to year.
It’s, it’s not that big of a deal.
Yolanda Padron: As an asset manager taking this on, I’d probably have started preparation on this project a lot earlier than other of my projects like I do. I know that usually there’s, you know, we’ve talked about the different teams, right, throughout the stages of the project until it goes into operations, [00:18:00] but.
And usually you don’t have a lot of time to prepare to, to make sure all of your i’s are dotted and t’s are crossed, um, by the time you take the project and operations from a commercial standpoint. But this project, I think would absolutely, like you, you would need to make sure that a lot of the, of the things that you’re, that might be issues for some of your projects like aren’t issues for this project.
Just to make sure at least the first few years you can. You can avoid a lot of, a lot of turmoil that the pricing and the disputes and the technical issues are gonna cause you, because I feel like it’s just, there’s, there’s just so many things that just keep this side, just keeps on getting hit, you know?
Allen H: Well, I, I guess the question is from my side, Yolanda, is obviously inflation, when this project started was pretty consistent, like one point half, 2%. It was very flat for a long time. And interest rates, if you remember when this project started, were very, very low. Almost [00:19:00] nonexistent, some interest rates.
Now that’s hugely different. How does a contract get set up where a vineyard can’t raise prices? It would just seem to me like you would have to tie some of the price increase to whatever the inflation rate is for the country, maybe even locally, so that if there were a, a war in Ukraine or some conflict in the Middle East.
That you, you would at least be able to, to generate some revenue out of this project because at some point it becomes untenable, right? You just can’t afford to operate it anymore. And,
Yolanda Padron: and I think, um, I, I haven’t, I obviously haven’t read the, the contracts themselves, but I know that there’s sometimes there, it’s pretty common for a PPA to have some sort of step up year by year.
And it’s usually, it can be tied to, um, the CPI for. Like the, the change in CPI for the year to year. So you’re [00:20:00] absolutely like, right, like maybe, I mean, hopefully they’re, they’re not just tied to the fixed 69 bucks per megawatt hour. Um, but, but yeah, to, to your point like that, that price increase could, could really save them.
Now that we’re, we’re talking the, the increase in, in inflation right now and foreseeable future,
Allen H: if you think about what electricity rates are up in the northeast. I think I was paying 30 cents a kilowatt hour, which is 300. Does that sound right? $300 a megawatt hour. Delivered at the house, something like that.
Right? So
Yolanda Padron: prices in the northeast are crazy to me,
Allen H: right? They’re like double what they are in North Carolina. Yeah.
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Yolanda Padron: you millions.
Allen H: Well, sometimes building a wind farm turns out more than expected construction workers at a 19 turbine wind project in lower Saxony Germany under Earth. What experts call the largest Bronze age Amber Horde ever found? The region, the very first scoop of an excavator brought up bronze and amber artifacts that stopped construction and brought archeologists back to the site.
Uh, the hoard has been dated between [00:22:00] 1500 and 1300 DCE and is believed to have belonged to at least three. Status women possibly buried as a religious offering. Now as we push further and further across Germany with wind turbines and solar panels for, for that matter, uh, we’re coming across older sites, uh, older pieces of ground that haven’t been touched in a long time and we’re, we’re gonna find more and more, uh, historically significant things buried in the soil.
What is the obligation? Of the constructor of this project and maybe across Europe. I, I would assume in the United States too, if we came across something that old and America’s just not that old to, to have anything of, of that kind of, um, maybe value or historically significant. What is the process here?
Rosemary Barnes: I assume that they’ve gotta stop, stop work. Um, yeah, that’s my, my understanding and I don’t think, do you have [00:23:00] grand designs in America?
Allen H: I don’t know what that is. Yes.
Rosemary Barnes: So missing out by not having that chat. It’s a TV show about people who are building houses or doing, um, ambitious renovations, and it just, it follows, it follows them.
You can learn a lot about project management or. The consequences if you decide that you don’t need to, project management isn’t a thing that you need to do. Um, anyway. I’m sure that in some of those ones I’ve seen they have had work stop because in their excavation they found a, um, yeah, some, some kind of relic, um, from the, from the past.
So based on that very well-credentialed experience that I have, I can confidently say that they would be stopping stopping work on that site. I mean, it’s so bad, bad for the developer, I guess, but it’s cool, right? That they’re, you know, uncovering, uh, new archeology and we can learn more about, you know, people that lived thousands of years ago.
Allen H: It, it does seem [00:24:00] like, obviously. Do push into places where humans have lived for thousands of years. We’re going to stumble across these things. Does that mean from a project standpoint, there’s, there’s some sort of financial consequence, like does the lower Saxony government contribute to the wind turbine fund to to pay the workers for a while?
’cause it seems like if they’re gonna do an archeological dig. That that’s gonna take months at a minimum, may, maybe not, but it usually, having watched these things go on it, it’s. It’s long.
Rosemary Barnes: But wouldn’t that be something that you’d have insurance for?
Allen H: Oh, maybe that’s it.
Rosemary Barnes: You know, it seems to me like an insurable, an insurable thing, like not so hard to, it would’ve affected plenty of other, like any project that involves excavation in Europe would come with a risk of, um, finding Yeah.
An archeological find. And having work stopped, I would assume.
Allen H: Yolanda, how does that work in the United States do, is there some insurance policy towards finding [00:25:00] a. Ancient burial ground and what happens to your project?
Yolanda Padron: I don’t know. I, um, the most I’ve heard has been, it’s just talking to like the government and like the local government and making sure that you have all your permits in place and making sure, you know, you might need to, to have certain studies so you know, you might not have to get rid of the whole wind farm or remove the hole wind farm, but at least a section.
Of it has to be displaced from what you originally had thought. I don’t know. I know it happens a lot in Mexico where you get a lot of changes to construction plans because you find historical artifacts or obviously not everybody does this, but like. Tales of construction workers who will like, find, they’re so jaded from finding historical artifacts that they just kind of like take and then dump them to the next plot over to not deal with it right now.
Not that it’s anything ethical, uh, or done by everybody, [00:26:00] uh, but it’s, but, but it’s a common occurrence, a relatively common occurrence.
Allen H: You would think it where a lot of wind turbines are in the United States, which is mostly Texas and kind of that. Midwest, uh, wind corridor that they would’ve stumbled across something somewhere.
But I did just a quick search. I really hadn’t found anything that there wasn’t like a Native American burial ground or something of that sort, which they previously knew. For the most part. It’s, so, it’s rare that, that you find something significant besides, well, maybe used some woolly mammoths tusks or something of that sort.
Uh, in the Midwest, it’s, it’s, so, it’s an odd thing, but is there a. A finder’s fee? Like do does the wind company get to take some of the proceeds of, of this? Trove of jewelry.
Rosemary Barnes: I, I would be highly surprised.
Allen H: Well, how does that work then? Rosemary?
Rosemary Barnes: I’d be highly surprised if that’s the case in Europe. I bet it would happen like that in America.
Allen H: Sounds like pirate bounty in a sense.
Rosemary Barnes: In, in Australia it wouldn’t be like that because [00:27:00]you, when you own land, you don’t actually. You, you own the right to do things from surface level and above, basically. I don’t know how excavation works. So you don’t generally have a a right to anything you find like that?
I mean, you shouldn’t either. It’s not, it’s not yours. It’s a, it belongs to the, I don’t know, the people that, that were buried. When you then to the, the land, like, I guess. The government in some way. I mean, in Australia it’s, um, like we don’t have so many archeological fines that you would find from digging.
I mean, it’s not that there’s none, but there’s not so many like that. But it is pretty common that, you know, there are special trees, um, you know, some old trees that predate, uh, white people arriving in Australia. And, um, you know, that have been used for, you know, like it might have a, a shield that’s been, um.
Carved out of it. Or, uh, hunting. Hunting things, ceremonial things, baskets, canoes, canoe like things, stuff like that. They call ’em a scar [00:28:00] tree ’cause they would cut it out of a living, living tree. And you know, so when you see a tree with those scars and that’s got, um, cultural significance. There’s also, you know, just trees that were, um.
That that was significant for cultural reasons and so you wouldn’t be able to cut down those trees if you were building any, doing any kind of development in Australia and a wind farm would be no different. I know that they are, there are guidelines for, if you do come across any kind of thing like that or you find any anything of cultural significance, then you have to report it and hopefully you don’t just move it onto the neighboring property.
Allen H: I know one of the things about watching, um. Some crazy Canadian shows is that. Uh, you have to have a Treasure Hunter’s license in Canada. So if you’re involved in that process, like you can’t dig, you can’t shovel things, only certain people can shovel. ’cause if they were to find something of value, you.
You’ll get taxed on it. So there’s just a lot of rules [00:29:00] about it. Even in Canada,
Rosemary Barnes: if I was an indigenous Australian and you know, some Europe person of European descent came and found some artifacts, uh, aboriginal. Artifacts. I would be pissed if they just took it and sold it. Like that’s just clearly inappropriate right.
To, to do that. So you, I don’t think it should be a free for all. If you find artifacts of cultural significance and you just, it’s, you find its keepers that, that doesn’t sound right to me at all.
Allen H: Can we talk about King Charles II’s visit to the United States for a brief moment?
Uh, he is a really good ambassador, just like, uh, the queen was forever. He’s, he does take it very seriously and the way that he interacted with the US delegation was remarkable at times in, in terms of knowing how to deal with somebody that there’s a war going on right now. So there’s a lot [00:30:00] happening in the United States that, uh, not only could it be.
Uh, respecting both sides of the UK and the United States’ position in a, in a number of different areas, but at the same time being humorous, trying to build bridges. Uh, king Charles, uh, had the scotch whiskey tariffs removed just by negotiating with President Trump, and sometimes that’s what it takes.
It’s a little bit of, uh. Being a good ambassador.
Allen H: Yeah. The very polished you would expect that. Right? But this is the first visit of. The king to the United States, I believe. ’cause he, he’s been obviously as a prince many, many, many times to the United States. [00:31:00]But this time as, as a, the representative of the country, the former representative or head of the country, which was unique.
I think he did a really good job. And I wish he, they would’ve talked about offshore wind. Maybe he could’ve calmed down the administration on offshore wind.
Rosemary Barnes: I bet that’s one of the, the goals. I mean, that’s an industry that’s important to. So
Allen H: I wonder if that happened actually. ’cause that’s not gonna be reported in, in the news, but how the UK is going on its own way in terms of electrification and I guarantee offshore wind had to come up it.
Although I have been not seen any article about it, I, I find it hard to believe that King Charles being the environmentalist that he is, and a proponent of offshore wind for a long time. Didn’t bring it up and try to mend some fences.
Rosemary Barnes: Maybe he’s playing the long game though. I mean, Trump is pretty, he’s transactional, but he also, you know, he has people that he really likes and you know, will act in their interests.
So maybe it’s enough to just be [00:32:00] really liked by Trump, and then that’s the smartest way you can go about it.
Allen H: Did you see the gift that King Charles presented to, uh, the US this past week?
It was a be from, uh, world War II submarine, which was the British, I dunno what the British called their submarines, but it was, the name of it was Trump. So they had the bell from. The submarine when it had been commissioned and they, they gave that to the United States, or give to the president. It goes to the United States.
The president doesn’t get to keep those things, but it was such a smart, it’s a great president. It’s such a smart gift, and somebody had to think about it and the king had to deliver it in a way that got rid of all the noise between the United States and the uk. Brought it back to, Hey, we have a lot in common [00:33:00] here.
We shouldn’t be bickering as much as we are. And I thought that was a really smart, tactful, sensible way to try to men some fences. That was really good. That wraps up another episode of the Uptime Wind Energy Podcast. If today’s discussion sparked any questions or ideas, we’d love to hear from you. Reach out to us on LinkedIn.
Don’t forget to subscribe, so you never miss this episode. And if you found value in today’s conversation, please leave us a review. It really helps other wind energy professionals discover the show. For Rosie and Yolanda, I’m Allen Hall and we with. See you’re here next week on the Uptime Wind Energy Podcast.
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