In this episode, we explore Meta’s shift to natural gas for AI data centers, analyze a major Mingyang offshore turbine blade failure, and discuss Shell’s head of renewables moving to Ørsted’. Fill out our Uptime listener survey and enter to win an Uptime mug!
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Allen Hall: If you want to know why turbine blades are disappearing from social media and why Shell’s Renewables Chief is jumping to worsted and why META is betting big on natural gas, stick around. Plus, we’ve got a special announcement, a chance to win an exclusive Uptime Podcast mug that even I don’t have yet.
You’re listening to the Uptime Wind Energy Podcast brought to you by BuildTurbines. com. Learn, train, and be a part of the clean energy revolution. Visit BuildTurbines. com today. Now here’s your hosts, Allen Hall, Joel Saxum, Phil Totaro, and Rosemary Barnes.
Allen Hall: We’ve got something new for uptime listeners.
We’re running a quick listener survey to learn more about what you love about the show and how we can make it even better. And there is an exciting part to this. Everyone who completes and leaves an email address will be entered to win an exclusive Uptime podcast mug. Now, I do not have one of these podcast mugs, so whoever wins this, hopefully I get a second hand one or something.
Somebody can throw me a mug. But the survey will take about five minutes of your time, and your feedback is really needed to help shape the future episodes of the show. And whether you’re a long time listener or have just joined us recently, we’d We want to hear from you. So I need you to go to uptimewindenergy.
com or just check the show notes to participate in the survey. So we’d appreciate if you would do that. And we have a couple other things happening. One of which is Wind Energy O& M Australia film where everybody’s going to be on February 11th and 12th in Melbourne. And we have a number of sponsors that we can announce this week.
Joel Saxum: So sponsorships and the people joining us at the show will be from Tilt Renewables, Worley, Aerones and RigCom. We’ve got a bunch of other people signed up too. To date, we’ve got quite a few operators, some ISPs, some cool technology companies, and other people’s that are going to be in attendance along with some speakers.
And we’re going to start releasing. Some agenda points and some of the speakers and panelists and roundtables. So the goal of, one of the goals of the conference is to drive engagement with the crowd because we want everybody to leave there with insights that they can take back and actually do something to their wind farms.
We want to help. We want to help make it more profitable. We want to help make operational decisions and drive some success at the field level. So that’s the goal of the show. And we hope you’ll join us.
Allen Hall: Yeah. The conference is going to tackle crucial topics that directly impact operations, leading edge erosion, lightening protection, CMS, insurance, life extension strategy.
So this is your chance to connect with industry leaders and gain. Some practical experience and insights that you can implement immediately. So you need to secure your spot by visiting windaustralia. com. And down in Houston, Joel, we have Active Training Team. They’re going to be giving a demonstration of their Thrive USA product, which is a safety training seminar, a live interactive.
It’s the most impactful training seminar for safety I have ever been at. You want to Talk about what is all involved in the Thrive USA, Joel.
Joel Saxum: Yeah, it’s a step change in training. It’s experiential. I know that’s a weird word, but Alan and I and Claire, our producer, went through this training in Boston a few months ago.
And we’re sitting in the crowd and we’re at tables with people from all kinds of different companies and levels of the company so that everybody’s intermixed. And then all of a sudden, They’re going through a little bit of a presentation and a few actors, real actors, like Screen Actors Guild, card carrying people come through the door and they’re fighting and yelling at each other and going through the scenario.
And then all stop. There’s someone that maintains the, that would be flow of the event. And they say, okay, what do you think about this? And you’re getting engaged and you’re thinking. And just talking about this right now, it reminded me of what happened while we were there. And I have goosebumps on my arms that are popping up because they’re it’s.
It hit me when we were there internally. I’ve never been through a training where I left in thinking like, wow, that was impactful. I am actually thinking about this. I’d like to action some of these things in my day to day life. We did breakout sessions. We talked through things. It was fantastic. So if you have the opportunity we would love to see you in Houston.
It’s going to be January 24th. Down by the medical center. And if you want some details on it, of course, you can get a hold of us at the show any either Alan or I can point you in the right spot. Joel.saxum@wglightning.com or feel free to reach out to Florence at the active training team. She’s guiding the whole process, so florence@activetrainingteam.co.uk can be your contact there, and we hope to see you in January there in Houston.
Allen Hall: Yeah, we’ll see you in Houston and the website for Active Training Team in the U. S. is ActiveTrainingTeam. us, so check that out.
Unlock your wind farm’s best performance at Wind Energy O& M Australia, February 11th to 12th in sunny Melbourne. Join industry leaders as they share practical solutions for maintenance, OEM relations, and asset management.
Discover strategies to cut costs. Keep your assets running smoothly and drive long term success in today’s competitive market. Register today and explore sponsorships at www. windaustralia. com.
Allen Hall: In the latest PES Wind Magazine, it’s Q4 of 2024. You can go online and read it yourself at peswind. com. Interesting article from DSHIP carriers, and DSHIP has designed a new carrier of blades. And it’s really interesting because it’s a new approach on how to move blades around offshore. And Joel, being our offshore expert, you want to explain these fun things about the D500 ship?
Joel Saxum: Yeah, I think that what we need to understand first is that we’ve been doing offshore wind for a long time. And we’re ready for a step change. We’re ready to see things turn over into new innovative techniques that are going to make things better. So when you talk shipping with anything, it’s always about efficiency, fuel burn, how can we get things on offshore better and The the DSHP team has taken all of this into consideration and making a purpose built vessel just for transport, transporting wind turbine parts.
And when you say that offshore, usually that doesn’t happen. A vessel is usually multi purpose because you want to make sure that you have a contract where someone can rent it out and have it on the lease for a long time and use it for multiple kinds of different things and transporting this or transporting that.
But what they’ve done here is made a vessel that’s super efficient, that’s specifically designed and built for optimum use for transporting wind turbine parts. So the hull has been optimized. The way you load things has been optimized. The way you unload things has been optimized even all the way down to how the crew gets around the vessel and what their walk times are in between areas of the vessel that they need to do their jobs.
That’s crazy impressive. The other things that they’ve done is make sure that this thing is future proofed. And future proof means the next generation of fuels, whether we get to the point where we’re using ammonia or hydrogen or some other kind of power the propulsion units in this vessel can be swapped over to what that next generation looks like.
The D Ship team in their new D 500 vessels, this is what they’re calling this, they have taken some really innovative steps to making offshore wind in their part of the supply chain, More efficient and more cost effective.
Allen Hall: Yeah, it’s a really interesting ship design. It’s going to be built in China. But if you want to read more about this ship and all the things that DShip is up to, go to PESWind.
com, download your issue, and read it for yourself. Good stuff in there. As wind energy professionals, staying informed is crucial, and let’s face it, difficult. That’s why the Uptime Podcast recommends PES Wind magazine. PES Wind offers a diverse range of in depth articles and expert insights that dive into the most pressing issues facing our energy future.
Whether you’re an industry
veteran or new to wind, PES Wind has the high quality content you need. Don’t miss out. Visit peswind. com today.
Allen Hall: In a significant shift in data center power strategies, Major technology companies, energy companies are turning to, of all things, natural gas to bridge the power for these growing, power hungry artificial intelligence infrastructures, these data centers.
And Meta is probably the key one at the minute. And they are planning a site in Louisiana that is going to be using natural gas as being provided through Intergy. And they need about two and a half years. gigawatts of electricity over a 15 year period. And Entergy is going to be fast tracked in the construction of three facilities to support this 10 billion data center project.
Now, Joel, first off, and Rosemary, why are we building data centers in Louisiana? What’s driving that? And why natural gas instead of a renewable?
Joel Saxum: It’s historically easy to get large capital projects done in that state because of the way the governments are set up and the way the parishes control things.
It’s pretty easy to get the wheels greased and get a large capital project moving. So that’s one thing in Louisiana. Other thing in Louisiana is energy is fairly cheap. The weather’s decent, like you don’t have to fight a lot of weird things. But if I was to say why gas, I think that’s a different Conversation.
For one, in Louisiana, renewable energy generation is not super prevalent, right? They don’t have wind farms. Solar farms can be built there. Yes. However, in a data center that is going to be a need a 1. 5 gigawatt facility. That means it’s so big. It’s a 10 billion project. That means it’s so big that you can’t afford to have intermittent power.
And, as we are on the show here, we love renewables and we want wind and solar and battery storage and all these great things to happen. At some levels, natural gas, in this case, just makes more sense. Thanks. Because you need that continuous power, you’re going to have continuous power demand.
This thing is going to be built behind the grid. I imagine they’ll still connect it to the grid so they can do some power triaging if they need to. But it will be built, for the most part, behind the grid. So you don’t have as much government oversight, you don’t have as much looking in on it. And in that level, if you just want to have this one data center sitting there by itself, chugging and doing its thing, a 100 percent like kind of steady load power supply is more effective than it is to have inter the intermittency of renewables.
I don’t know. Rosemary, what’s your opinion on that?
Rosemary Barnes: I’ve got a list actually that I’m keeping track of planning a video on AI, maybe a couple, but I’m keeping track of all the announcements about data center and big tech companies and their power purchase agreements or investments that they’re making in energy.
And everything is on there. There’s nuclear, there’s geothermal, a big announcement from Google just a couple of weeks ago about wind and solar being their preference for future plans. Data centers, they’re in a huge period of growth. It’s not necessarily really certain how much energy they’re going to need, but they know that they don’t want to be short because, if you miss out or you don’t have enough capacity, that’s a big loss for them.
Whereas if you. Sign a, or, start looking into a project now, not even signing anything, then it’s not actually that much lost if you realize that you don’t need it. So I think that you can’t use like the number of announcements gives us this idea that this is like the biggest user of energy in the world.
And it is so far from that. We’re not going to see this amount of activity in the next few years. I’m sure it will be a lot. Yeah, but that’s my thought. And I just think it’s, they want energy of any kind, pretty much, preferably clean. And if it can’t be clean, then, like they, they need it, whatever they can get.
Allen Hall: Meta is trying to do a carbon offset while meanwhile ExxonMobil, which is diving into this power generation business is specifically going to use natural gas, Plants with carbon capture to try to remove 90 percent of the emissions. Meta’s not doing that. Meta’s saying, we’ll put in some more solar and wind farms to offset what we’re doing in Louisiana.
Why is the big Oil and gas company doing carbon capture and Meta is not.
Joel Saxum: ExxonMobil knows how to do it too, right? Carbon capture is very much about understanding, underspeak, understanding subsurface geophysics and understanding where you can store this stuff and how you can do it, how you drill for this, how you build a facility that can inject deep underground.
ExxonMobil knows how to do that in spades as well, right? The other side of the thing where ExxonMobil is their headquarters in Houston and around Houston. This is a weird geophysical thing, but you have one of the highest concentrations of salt domes. In the world, in a lot along the Gulf coast and along the Louisiana deltas and stuff.
That’s why there’s a lot of oil and gas in there. One of the reasons, but those are picture perfect for carbon sequestration to capture. And there’s a lot of other things down there, other kinds of formations, subsurface that make Louisiana and Texas prime for all of this carbon sequestration work.
And at the end of the day, ExxonMobil knows how to do it. Meta doesn’t have a clue unless they grab some kind of subcontractor.
Phil Totaro: Yeah, but they would, they would do that anyway, because it’s not their core competency. So they would necessarily partner with somebody and be the capital provider to it, but they could do that with anybody.
I will go back to, there is more than a billion dollars. That the U. S. Department of Energy has allocated towards, carbon capture and sequestration projects just this year alone. As, as far as grant money and other incentives for companies to, to do that sort of thing. If the government’s throwing free money at them to just even try out that technology, they’re gonna do it.
I think at the end of
Joel Saxum: the day, you have to look at what the, what it looks like for ESG stamps, ESG plans, marketing, and PR from some of these companies as well. Nobody cares about ESG anymore. But you still have, they still, there’s still written items on quarterly statements that say this and that, and we’re going to do this.
And we’re going to do that. So maybe sometime along the line, Meta has said, we’re going to do more renewable generation. Whereas Exxon Mobil being an oil and gas company says, we’re going to do it this way.
Allen Hall: Let’s stick in oil and gas for a minute. We’ll Shell’s head of renewables for America, Amanda Dash, will be taking the helm of Orsted’s U.
S. operations starting mid January. That’s a big move. And this transition happens at a pivotal moment for both companies because Shell is trying to get out of renewables and Orsted is trying to survive in it. But picking Amanda Dash for that C suite position is interesting because you’ve got someone who knows a lot about oil and gas and a lot about offshore.
And then renewable. So
Phil Totaro: those people tend to be hard to find, Phil. And somebody who’s got potentially better connections with people in government. Which I think was, yeah, potentially one of Orsted’s challenges coming over here and trying to develop projects in New York, New Jersey offshore. While they still have an onshore wind and solar portfolio as well, it’s relatively small compared to what they’re doing with they’re offshore pipelines, so that’s gonna dominate and somebody with background from Shell will hopefully help them take another step.
At one point,
Allen Hall: Orsted had a larger market cap than Shell, which is now hard to believe. For five minutes. For a little while, yeah, they did, but that actually happened. The world flipped over, right? The polls reversed something. But the, now you’re taking, but you’re, now you’re taking that sort of key person out of Shell.
and plug them in into Orsted. Orsted has a lot of projects going on in the U. S. right now. Obviously there’s a little bit on the offshore, which are problematic, but they also have a ton of onshore projects going on that they’re trying to navigate, which I, which may be their biggest revenue source.
Joel Saxum: Yeah, I know Orsted’s got quite a few onshore wind farms and they’re building some new ones as we speak, but one of the other things I want to touch on was the knowledge that may come with. Ms. Dash coming from Shell. Shell did a lot of exploration in the Gulf as far as offshore wind, and they’ve put a lot of money into R& D and some kind of technology development and ideas and information gathering in the background.
She’s coming over there also with some probably new information for the Orsted management team.
Allen Hall: Yeah, I totally agree upon that. It’s a new perspective for sure. It’s a very American perspective in an oil and gas perspective. And now’s the time, right? This is going to be fascinating.
The board meetings will be interesting, I think, because you really have a defined oil and gas person with a lot of knowledge plugged into this sort of Danish infrastructure.
Joel Saxum: I did say something that may be controversial, but this is from someone coming from an oil and gas background. Yeah, But no matter where it is in the world, oil and gas people tend to know how to get stuff done.
Whether that’s through relationships, or through capital engagement, or whatever. You can see that same story playing out over and over and over. No matter where you are in the world. I think that grabbing someone that’s been a part of one of those organizations is a good move.
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Allen Hall: If you’ve watched social media for that brief moment in time, you saw a Mingyang wind turbine. The Mingyang SE 18. X 20 megawatt turbine have a blade failure. Actually had two blade failures, according to reports. Now this is a big deal cause it has multiple levels to it.
First was the video that showed these blades toppling down and landing on the ground. And then they got quiet for about 24 hours and I couldn’t find any of those videos anymore or photos. It seemed to be a scrub from the internet. But then Ming Yang came back on LinkedIn social media and said that there was an incident of extreme abnormal conditions.
And while the turban had previously survived September’s super typhoon Yagi without issues something happened where it overloaded the blade structure. Now Rosemary is first to point out on LinkedIn to say how could it have been over the threshold of its strength capabilities? How did that happen?
Why didn’t you know that? Why wasn’t it tested? What really happened? I think that’s the question everybody has, is what really happened with that? Turban, was it truly some sort of unique air loading on it? Was it stopped? Was it rotor locked? They had a wind gust? What brought this set of blades down?
Rosemary, do you have any guess on that? Because the information we get out of China is really limited right now.
Rosemary Barnes: Yeah, it’s really interesting as well. I’m trying to pull up the post cause there’s some really interesting comments in there from people mostly with Western sounding names, but maybe working for some sort of Chinese company or yeah, something their work.
It’s obviously related to China somehow. So the Ming Yang post, I don’t have it with me now. And I will say, I haven’t found any posts that have been deleted or anything. I can still find plenty of examples of the images up there. So
Phil Totaro: On LinkedIn, but not on the web, greater. The source, some of the Chinese sources were removed, but we cataloged it.
So we, we still have it.
Rosemary Barnes: But yeah, the Ming Yang Post was saying, this is a prototype and it faced abnormal conditions, extreme abnormal conditions, I think it said. And so my response was did you make a mistake with your site your site assessment that you were surprised by the conditions?
Because obviously, wind turbines have to exist in the real world, and they also have to exist in places where you didn’t necessarily have the greatest data. There are ways of, extrapolating from, maybe one year’s worth of met data to get like a representative example of what it should experience in its lifetime.
And Ming Yang didn’t reply to me, but lots of other people did telling me that yeah, that the, cause I said, yeah, did you overestimate underestimate the loads that were the blade was going to see? And people said, no, they didn’t say that the loads were exceeded. They said that the conditions were abnormal.
And I thought obviously if you’ve got a mechanical failure, then At some point, there’s been a load that has exceeded a strength. That’s why things break, but I do take the point that it could have been that, like the control system was wrong or responded to August incorrectly or something, but it’s still a mistake.
A lot of people who I don’t think understand how Technology development process works and especially not the wind industry, but people saying, this is a prototype. That’s what’s supposed to happen to prototypes. And I say, absolutely not. You do obviously it’s a prototype because you haven’t ironed out absolutely every single kink in it.
But, like for a major failure, like the blade, you could see in the video, the blade just snapped. It snapped I don’t know, quite close to the root, not at the root, but quite close to the root. And it just broke off and fell away. That is something that for sure should have been ironed out well before the point that turbine.
It’s incredibly dangerous.
Phil Totaro: How dangerous is it though to end up Testing blades to where you have two on a single turban, and they have two turbans there, by the way, so they are still learning something, but they’ve failed two blades on a single turban that could have struck the tower. You can cause the whole thing to come down.
So that’s an incredibly dangerous way to,
Rosemary Barnes: For sure, the tower is damaged now. There’s no way that the rest of it, you’re not just going to wipe two new blades up there and carry on your merry way. And in fact, if the other one is still turning, I don’t think that’s very smart unless they have done a much better root cause analysis than what they have publicized.
And this is not uniquely Chinese, that no one ever tells you the real progress of their root cause analysis until they have really got it dialed in. They know exactly what caused it and they have actions in place to fix it. But that’s the time that Companies tend to want to start talking about it.
Joel Saxum: I think at the end of the day, we’ve seen disinformation come from that end of the world. They didn’t engineer this thing correctly and it failed. They made a mistake. Move on. That’s what that’s the reality. In my opinion, it’s a huge blade. It’s like a, how long is this blade? 143 meter blade.
That’s ridiculous. That 143 meters. That’s a football field and a half or a pitch and a half. Like at some point in time, we’re going to get to the point where materials science is outliving what the reality of what we’re trying to build. And that’s what happened here. In my opinion, this thing failed. And now they’re trying to cover up that it failed.
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Allen Hall: Monster. com has published a comprehensive guide on office holiday party etiquette. Offering practical advice for navigating these professional social events. Now, they recommend, and you can chime in here, everybody, arriving 15 to 30 minutes after the party starts, being sociably late, and plan to stay for at least an hour, and follow the dress code.
This is the one that I think gets everybody in at least situations hyped around. Whether it’s ugly sweaters or formal business attire. Try to stick to that general area and use the opportunity to network with colleagues and other people that you don’t necessarily get to see all year. This is just a fun thing to do, and avoid the politics, religion, and workplace complaints.
Now, workplace complaints always seem to pop up. No matter where you are, but the one thing I think has changed over time, and hopefully it continues on this pathway, is the PDAs, the sexist drinking, and the inappropriate dancing. Not that long ago, everybody wow yeah, some really awkward situations would pop up at holiday parties that you wouldn’t see the rest of the year.
And it had consequences. Any recommendations as you go to holiday parties from the group here?
Joel Saxum: I think there’s an important one here that says, get permission before posting any photos or videos on social media. I would switch that one to just don’t. Just don’t do it. The other thing I want to say is because I’ve been I’ve worked for a couple international companies, as everybody on this panel has, The, how things are handled in different countries and different places are very different.
This is a monster. com list of probably what you should do in the United States. A Danish Christmas party is much different than a United States Christmas party. So I think that understanding where you are and the people around you being a little bit of aware and having some introspect on the situation is very important.
Allen Hall: Rosemary, you didn’t go to any LM holiday parties?
Rosemary Barnes: I did. I miss them so much. Danish Christmas party is the best. It’s nearly the best thing about living in Denmark. It might be the best thing. They’re so good.
Joel Saxum: You have to sign an NDA when you walk in. Yeah. They take your phone away from you?
Rosemary Barnes: They should, they didn’t, but they should.
And actually, when you moved to Denmark or at least back when I did, they had a program where they give you language classes and also it’s a bit of a cultural education. And one of the things I remember learning at that class was that be careful of the office Christmas party. There’s usually a peak in divorces shortly after.
It’s because of people cheating on their spouses with their colleagues. I never saw that, so I think that might be an urban myth, but yeah, they do get a bit wild.
Phil Totaro: Alternatively, you, since most people, start a new job in January, you can do whatever you want at the old Christmas party, if you’re leaving the company, like You can tell everybody what you think, exactly what you think before you leave. Yeah, do a Costanza. I’m gonna tell all you people what I think about you.
Allen Hall: Yeah, the one I didn’t like was when people started fighting. That just got to be ridiculous. Not here, not now, but he’s trying to have a nice time.
Take it out to the parking lot. What kind of Christmas
Joel Saxum: parties did you go to? New Jersey. Yeah, that makes sense. This week’s Wind Farm of the Week is the Crocker Wind Farm up in South Dakota that is owned by National Grid Renewables. This wind energy project was built by Wonset Construction using GE 2.
7116 wind turbines. It’s a 200 megawatt project. It has virtual power purchase agreements with Walmart and Cargill. Cargill being really important up in the Upper Midwest because they’re a seed company. They do a lot of stuff with the agricultural side of things. Thanks. But one thing really interesting about this wind farm is when they set it up, of course, there’s the 83 million in direct economic impact and there’s 36 million in new tax revenue and 175 construction and operation jobs.
We see those stats for a lot of wind farms, but what they did here was they put together a community fund it’s a charitable fund. So if you’re in that community, you can apply to get these funds. Every year it reloads. And it’s 40, 000 available every year for the next 20 years from when this wind farm was started.
Adding up to about 800, 000 in charitable funding. So if you want to, put new paint down on the football field in the town, you can apply for a little bit of funding. If you want to do something else for the schools or the four H Club or just the community center or something of that sort.
Groups get together and they can pull from this pool of money that is provided by National Grid Renewables as a part of this wind farm. So I think that’s really cool ’cause it’s direct giving back it’s dollars and cents and people can get on board with it. So kudos to national good Renewables for setting up that $800,000 charitable fund at the Crocker Wind Farm.
All of the men and women that are operating that wind farm this week, you are the Uptime Wind Energy podcast wind farm of the week.
Allen Hall: That’s going to do it for this week’s Uptime Wind Energy podcast, and thanks for listening. Please give us a five star rating on your podcast platform and subscribe in the show notes to our Substack Uptime Tech News, our weekly newsletter, and check out Rosie’s YouTube channel, Engineering with Rosie, and we’ll see you here next week on the Uptime Wind Energy podcast.
https://weatherguardwind.com/new-orsted-us-head-mingyang/
Renewable Energy
Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage
Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage
This exclusive article originally appeared in PES Wind 4 – 2025 with the title, Operations take center stage in wind’s next chapter. It was written by Allen Hall and other members of the WeatherGuard Lightning Tech team.
As aging fleets, shrinking margins, and new policies reshape the wind sector, wind energy operations are in the spotlight. The industry’s next chapter will be defined not by capacity growth, but by operational excellence, where integrated, predictive maintenance turns data into decisions and reliability into profit.
Wind farm operations are undergoing a fundamental transformation. After hosting hundreds of conversations on the Uptime Wind Energy Podcast, I’ve witnessed a clear pattern: the most successful operators are abandoning reactive maintenance in favor of integrated, predictive strategies. This shift isn’t just about adopting new technologies; it’s about fundamentally rethinking how we manage aging assets in an era of tightening margins and expanding responsibilities.
The evidence was overwhelming at this year’s SkySpecs Customer Forum, where representatives from over 75% of US installed wind capacity gathered to share experiences and strategies. The consensus was clear: those who integrate monitoring, inspection, and repair into a cohesive operational strategy are achieving dramatic improvements in reliability and profitability.
Takeaway: These options have been available to wind energy operations for years; now, adoption is critical.
Why traditional approaches to wind farm operations are failing
Today’s wind operators face an unprecedented convergence of challenges. Fleets installed during the 2010-2015 boom are aging in unexpected ways, revealing design vulnerabilities no one anticipated. Meanwhile, the support infrastructure is crumbling; spare parts have become scarce, OEM support is limited, and insurance companies are tightening coverage just when operators need them most.
The situation is particularly acute following recent policy changes. The One Big Beautiful Bill in the United States has fundamentally altered the economic landscape. PTC farming is no longer viable; turbines must run longer and more reliably than ever before. Engineering teams, already stretched thin, are being asked to manage not just wind assets but solar and battery storage as well. The old playbook simply doesn’t work anymore.
Consider the scope of just one challenge: polyester blade failures. During our podcast conversation with Edo Kuipers of We4Ce, we learned that an estimated 30,000 to 40,000 blades worldwide are experiencing root bushing issues. ‘After a while, blades are simply flying off,’ Kuipers explained. The financial impact of a single blade failure can exceed €300,000 when you factor in replacement costs, lost production, and crane mobilization. Yet innovative repair solutions, like the one developed by We4Ce and CNC Onsite, can address the same problem for €40,000 if caught early. This pattern repeats across every major component. Gearbox failures that once required complete replacement can now be predicted months in advance. Lightning damage that previously caused catastrophic failures can be prevented with inexpensive upgrades and real-time monitoring. All these solutions are based on the principle that predicted maintenance is better than an expensive surprise.
Seeing problems before they happeny, and potential risks
The transformation begins with visibility. Modern monitoring systems reveal problems that traditional methods miss entirely. Eric van Genuchten of Sensing360 shared an eye-opening statistic on our podcast: ‘In planetary gearbox failures, they get 90%, so there’s still 10% of failures they cannot detect.’ That missing 10% represents the catastrophic failures that destroy budgets and production targets. Advanced monitoring technologies are filling these gaps. Sensing360’s fiber optic sensors, for example, detect minute deformations in steel components, revealing load imbalances and fatigue progression invisible to traditional monitoring. ‘We integrate our sensors in steel and make rotating equipment smarter,’ van Genuchten explained.
Other companies are deploying acoustic systems to identify blade delamination, oil analysis for gearbox health, and electrical signature analysis for generator issues. Each technology adds a piece to the puzzle, but the real value comes from integration. The impact of load monitoring alone can be transformative.
As van Genuchten explained, ‘Twenty percent more loading on a gearbox or on a bearing is half of your life. The other way around, twenty percent less loading is double your life.’ With proper monitoring, operators can optimize load distribution across their fleet, extending component life while maximizing production.
But monitoring without action is just expensive data collection. The most successful operators are those who’ve learned to translate sensor data into operational decisions. This requires not just technology but organizational change, breaking down silos between monitoring, maintenance, and management teams.
In Wind Energy Operations, Early intervention makes the million-dollar difference
The economics of early intervention are compelling across every component type. The blade root bushing example from We4Ce illustrates this perfectly. With their solution, early detection means replacing just 24-30 bushings in about 24 hours of drilling work. Wait, and you’re looking at 60+ bushings and 60 hours of work. Early detection doesn’t just prevent catastrophic failure; it makes repairs faster, cheaper, and more reliable.
This principle extends throughout the turbine. Early-stage bearing damage can be addressed through targeted lubrication or minor adjustments. Incipient electrical issues can be resolved with cleaning or connection tightening. Small blade surface cracks can be repaired in a few hours before they propagate into structural damage requiring weeks of work.
Leading operators are implementing tiered response protocols based on monitoring data. Critical issues trigger immediate intervention. Developing problems are scheduled for the next maintenance window. Minor issues are monitored and addressed during routine service. This systematic approach reduces both emergency repairs and unnecessary maintenance, optimizing resource allocation across the fleet.
Turning information into action
While monitoring generates data, platforms like SkySpecs’ Horizon transform that data into operational intelligence. Josh Goryl, SkySpecs’ Chief Revenue Officer, explained their evolution at the recent Customer Forum: ‘I think where we can help our customers is getting all that data into one place.
The game-changer is integration across data types. The company is working to combine performance data with CMS data to provide valuable insights into turbine health. This approach has been informed by operators across the world, who’ve discovered that integrated platforms deliver insights that siloed data can’t.
The platform approach also addresses the reality of shrinking engineering teams managing expanding portfolios. As Goryl noted, many wind engineers are now responsible for solar and battery storage assets as well. One platform managing multiple technologies through a unified interface becomes essential for operational efficiency.
The Integration Imperative for Wind Farm Operations
The most successful operators aren’t just adopting individual technologies; they’re integrating monitoring, inspection, and repair into a seamless operational system. This integration operates at multiple levels.
At the technical level, data from various monitoring systems feeds into unified platforms that provide comprehensive asset visibility. These platforms don’t just display data; they analyze patterns, predict failures, and generate work orders.
At the organizational level, integration means breaking down barriers between departments. This cross-functional collaboration transforms O&M from a cost center into a value driver. Building your improvement roadmap For operators ready to enhance their O&M approach, the path forward involves several key steps:
Assessing the Current State of your Wind Energy Operations
Document your maintenance costs, failure rates, and downtime patterns. Identify which problems consume the most resources and which assets are most critical to your wind farm operations.
Start with targeted pilots Rather than attempting wholesale transformation, begin with focused initiatives targeting your biggest pain points. Whether it’s blade monitoring, gearbox sensors, or repair innovations, starting with your largest issue will help you see the biggest benefit.
• Invest in integration, not just technology: the most sophisticated monitoring system is worthless if its data isn’t acted upon. Ensure your organization has the processes and culture to transform data into decisions – this is the first step to profitability in your wind farm operations.
Build partnerships, not just contracts: look for technology providers and service companies willing to share knowledge, not just deliver services. The goal is building capability, not dependency.
• Measure and iterate: track the impact of each initiative on your key performance indicators. Use lessons learned to refine your approach and guide future investments.
The competitive advantage
The wind industry has reached an inflection point. With increasingly large and complex turbines, monitoring needs to adapt with it. The era of flying blind is over.
In an industry where margins continue to compress and competition intensifies, operational excellence has become a key differentiator. Those who master the integration of monitoring, inspection, and repair will thrive. Those who cling to reactive maintenance face escalating costs and declining competitiveness.
The technology exists. The business case is proven. The early adopters are already reaping the benefits. The question isn’t whether to transform your O&M approach, but how quickly you can adapt to this new reality. In the race to operational excellence, the winners will be those who act decisively to embrace the efficiency revolution reshaping wind operations.
Unless otherwise noted, images here are from We4C Rotorblade Specialist.

Contact us for help understanding your lightning damage, future risks, and how to get more uptime from your equipment.
Download the full article from PES Wind here
Find a practical guide to solving lightning problems and filing better insurance claims here
Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage
Renewable Energy
BladeBUG Tackles Serial Blade Defects with Robotics
Weather Guard Lightning Tech

BladeBUG Tackles Serial Blade Defects with Robotics
Chris Cieslak, CEO of BladeBug, joins the show to discuss how their walking robot is making ultrasonic blade inspections faster and more accessible. They cover new horizontal scanning capabilities for lay down yards, blade root inspections for bushing defects, and plans to expand into North America in 2026.
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: Chris, welcome back to the show.
Chris Cieslak: It’s great to be back. Thank you very much for having me on again.
Allen Hall: It’s great to see you in person, and a lot has been happening at Blade Bugs since the last time I saw Blade Bug in person. Yeah, the robot. It looks a lot different and it has really new capabilities.
Chris Cieslak: So we’ve continued to develop our ultrasonic, non-destructive testing capabilities of the blade bug robot.
Um, but what we’ve now added to its capabilities is to do horizontal blade scans as well. So we’re able to do blades that are in lay down yards or blades that have come down for inspections as well as up tower. So we can do up tower, down tower inspections. We’re trying to capture. I guess the opportunity to inspect blades after transportation when they get delivered to site, to look [00:01:00] for any transport damage or anything that might have been missed in the factory inspections.
And then we can do subsequent installation inspections as well to make sure there’s no mishandling damage on those blades. So yeah, we’ve been just refining what we can do with the NDT side of things and improving its capabilities
Joel Saxum: was that need driven from like market response and people say, Hey, we need, we need.
We like the blade blood product. We like what you’re doing, but we need it here. Or do you guys just say like, Hey, this is the next, this is the next thing we can do. Why not?
Chris Cieslak: It was very much market response. We had a lot of inquiries this year from, um, OEMs, blade manufacturers across the board with issues within their blades that need to be inspected on the ground, up the tap, any which way they can.
There there was no, um, rhyme or reason, which was better, but the fact that he wanted to improve the ability of it horizontally has led the. Sort of modifications that you’ve seen and now we’re doing like down tower, right? Blade scans. Yeah. A really fast breed. So
Joel Saxum: I think the, the important thing there is too is that because of the way the robot is built [00:02:00] now, when you see NDT in a factory, it’s this robot rolls along this perfectly flat concrete floor and it does this and it does that.
But the way the robot is built, if a blade is sitting in a chair trailing edge up, or if it’s flap wise, any which way the robot can adapt to, right? And the idea is. We, we looked at it today and kind of the new cage and the new things you have around it with all the different encoders and for the heads and everything is you can collect data however is needed.
If it’s rasterized, if there’s a vector, if there’s a line, if we go down a bond line, if we need to scan a two foot wide path down the middle of the top of the spa cap, we can do all those different things and all kinds of orientations. That’s a fantastic capability.
Chris Cieslak: Yeah, absolutely. And it, that’s again for the market needs.
So we are able to scan maybe a meter wide in one sort of cord wise. Pass of that probe whilst walking in the span-wise direction. So we’re able to do that raster scan at various spacing. So if you’ve got a defect that you wanna find that maximum 20 mil, we’ll just have a 20 mil step [00:03:00] size between each scan.
If you’ve got a bigger tolerance, we can have 50 mil, a hundred mil it, it’s so tuneable and it removes any of the variability that you get from a human to human operator doing that scanning. And this is all about. Repeatable, consistent high quality data that you can then use to make real informed decisions about the state of those blades and act upon it.
So this is not about, um, an alternative to humans. It’s just a better, it’s just an evolution of how humans do it. We can just do it really quick and it’s probably, we, we say it’s like six times faster than a human, but actually we’re 10 times faster. We don’t need to do any of the mapping out of the blade, but it’s all encoded all that data.
We know where the robot is as we walk. That’s all captured. And then you end up with really. Consistent data. It doesn’t matter who’s operating a robot, the robot will have those settings preset and you just walk down the blade, get that data, and then our subject matter experts, they’re offline, you know, they are in their offices, warm, cozy offices, reviewing data from multiple sources of robots.
And it’s about, you know, improving that [00:04:00] efficiency of getting that report out to the customer and letting ’em know what’s wrong with their blades, actually,
Allen Hall: because that’s always been the drawback of, with NDT. Is that I think the engineers have always wanted to go do it. There’s been crush core transportation damage, which is sometimes hard to see.
You can maybe see a little bit of a wobble on the blade service, but you’re not sure what’s underneath. Bond line’s always an issue for engineering, but the cost to take a person, fly them out to look at a spot on a blade is really expensive, especially someone who is qualified. Yeah, so the, the difference now with play bug is you can have the technology to do the scan.
Much faster and do a lot of blades, which is what the de market demand is right now to do a lot of blades simultaneously and get the same level of data by the review, by the same expert just sitting somewhere else.
Chris Cieslak: Absolutely.
Joel Saxum: I think that the quality of data is a, it’s something to touch on here because when you send someone out to the field, it’s like if, if, if I go, if I go to the wall here and you go to the wall here and we both take a paintbrush, we paint a little bit [00:05:00] different, you’re probably gonna be better.
You’re gonna be able to reach higher spots than I can.
Allen Hall: This is true.
Joel Saxum: That’s true. It’s the same thing with like an NDT process. Now you’re taking the variability of the technician out of it as well. So the data quality collection at the source, that’s what played bug ducts.
Allen Hall: Yeah,
Joel Saxum: that’s the robotic processes.
That is making sure that if I scan this, whatever it may be, LM 48.7 and I do another one and another one and another one, I’m gonna get a consistent set of quality data and then it’s goes to analysis. We can make real decisions off.
Allen Hall: Well, I, I think in today’s world now, especially with transportation damage and warranties, that they’re trying to pick up a lot of things at two years in that they could have picked up free installation.
Yeah. Or lifting of the blades. That world is changing very rapidly. I think a lot of operators are getting smarter about this, but they haven’t thought about where do we go find the tool.
Speaker: Yeah.
Allen Hall: And, and I know Joel knows that, Hey, it, it’s Chris at Blade Bug. You need to call him and get to the technology.
But I think for a lot of [00:06:00] operators around the world, they haven’t thought about the cost They’re paying the warranty costs, they’re paying the insurance costs they’re paying because they don’t have the set of data. And it’s not tremendously expensive to go do. But now the capability is here. What is the market saying?
Is it, is it coming back to you now and saying, okay, let’s go. We gotta, we gotta mobilize. We need 10 of these blade bugs out here to go, go take a scan. Where, where, where are we at today?
Chris Cieslak: We’ve hads. Validation this year that this is needed. And it’s a case of we just need to be around for when they come back round for that because the, the issues that we’re looking for, you know, it solves the problem of these new big 80 a hundred meter plus blades that have issues, which shouldn’t.
Frankly exist like process manufacturer issues, but they are there. They need to be investigated. If you’re an asset only, you wanna know that. Do I have a blade that’s likely to fail compared to one which is, which is okay? And sort of focus on that and not essentially remove any uncertainty or worry that you have about your assets.
’cause you can see other [00:07:00] turbine blades falling. Um, so we are trying to solve that problem. But at the same time, end of warranty claims, if you’re gonna be taken over these blades and doing the maintenance yourself, you wanna know that what you are being given. It hasn’t gotten any nasties lurking inside that’s gonna bite you.
Joel Saxum: Yeah.
Chris Cieslak: Very expensively in a few years down the line. And so you wanna be able to, you know, tick a box, go, actually these are fine. Well actually these are problems. I, you need to give me some money so I can perform remedial work on these blades. And then you end of life, you know, how hard have they lived?
Can you do an assessment to go, actually you can sweat these assets for longer. So we, we kind of see ourselves being, you know, useful right now for the new blades, but actually throughout the value chain of a life of a blade. People need to start seeing that NDT ultrasonic being one of them. We are working on other forms of NDT as well, but there are ways of using it to just really remove a lot of uncertainty and potential risk for that.
You’re gonna end up paying through the, you know, through the, the roof wall because you’ve underestimated something or you’ve missed something, which you could have captured with a, with a quick inspection.
Joel Saxum: To [00:08:00] me, NDT has been floating around there, but it just hasn’t been as accessible or easy. The knowledge hasn’t been there about it, but the what it can do for an operator.
In de-risking their fleet is amazing. They just need to understand it and know it. But you guys with the robotic technology to me, are bringing NDT to the masses
Chris Cieslak: Yeah.
Joel Saxum: In a way that hasn’t been able to be done, done before
Chris Cieslak: that. And that that’s, we, we are trying to really just be able to roll it out at a way that you’re not limited to those limited experts in the composite NDT world.
So we wanna work with them, with the C-N-C-C-I-C NDTs of this world because they are the expertise in composite. So being able to interpret those, those scams. Is not a quick thing to become proficient at. So we are like, okay, let’s work with these people, but let’s give them the best quality data, consistent data that we possibly can and let’s remove those barriers of those limited people so we can roll it out to the masses.
Yeah, and we are that sort of next level of information where it isn’t just seen as like a nice to have, it’s like an essential to have, but just how [00:09:00] we see it now. It’s not NDT is no longer like, it’s the last thing that we would look at. It should be just part of the drones. It should inspection, be part of the internal crawlers regimes.
Yeah, it’s just part of it. ’cause there isn’t one type of inspection that ticks all the boxes. There isn’t silver bullet of NDT. And so it’s just making sure that you use the right system for the right inspection type. And so it’s complementary to drones, it’s complimentary to the internal drones, uh, crawlers.
It’s just the next level to give you certainty. Remove any, you know, if you see something indicated on a a on a photograph. That doesn’t tell you the true picture of what’s going on with the structure. So this is really about, okay, I’ve got an indication of something there. Let’s find out what that really is.
And then with that information you can go, right, I know a repair schedule is gonna take this long. The downtime of that turbine’s gonna be this long and you can plan it in. ’cause everyone’s already got limited budgets, which I think why NDT hasn’t taken off as it should have done because nobody’s got money for more inspections.
Right. Even though there is a money saving to be had long term, everyone is fighting [00:10:00] fires and you know, they’ve really got a limited inspection budget. Drone prices or drone inspections have come down. It’s sort, sort of rise to the bottom. But with that next value add to really add certainty to what you’re trying to inspect without, you know, you go to do a day repair and it ends up being three months or something like, well
Allen Hall: that’s the lightning,
Joel Saxum: right?
Allen Hall: Yeah. Lightning is the, the one case where every time you start to scarf. The exterior of the blade, you’re not sure how deep that’s going and how expensive it is. Yeah, and it always amazes me when we talk to a customer and they’re started like, well, you know, it’s gonna be a foot wide scarf, and now we’re into 10 meters and now we’re on the inside.
Yeah. And the outside. Why did you not do an NDT? It seems like money well spent Yeah. To do, especially if you have a, a quantity of them. And I think the quantity is a key now because in the US there’s 75,000 turbines worldwide, several hundred thousand turbines. The number of turbines is there. The number of problems is there.
It makes more financial sense today than ever because drone [00:11:00]information has come down on cost. And the internal rovers though expensive has also come down on cost. NDT has also come down where it’s now available to the masses. Yeah. But it has been such a mental barrier. That barrier has to go away. If we’re going going to keep blades in operation for 25, 30 years, I
Joel Saxum: mean, we’re seeing no
Allen Hall: way you can do it
Joel Saxum: otherwise.
We’re seeing serial defects. But the only way that you can inspect and or control them is with NDT now.
Allen Hall: Sure.
Joel Saxum: And if we would’ve been on this years ago, we wouldn’t have so many, what is our term? Blade liberations liberating
Chris Cieslak: blades.
Joel Saxum: Right, right.
Allen Hall: What about blade route? Can the robot get around the blade route and see for the bushings and the insert issues?
Chris Cieslak: Yeah, so the robot can, we can walk circumferentially around that blade route and we can look for issues which are affecting thousands of blades. Especially in North America. Yeah.
Allen Hall: Oh yeah.
Chris Cieslak: So that is an area that is. You know, we are lucky that we’ve got, um, a warehouse full of blade samples or route down to tip, and we were able to sort of calibrate, verify, prove everything in our facility to [00:12:00] then take out to the field because that is just, you know, NDT of bushings is great, whether it’s ultrasonic or whether we’re using like CMS, uh, type systems as well.
But we can really just say, okay, this is the area where the problem is. This needs to be resolved. And then, you know, we go to some of the companies that can resolve those issues with it. And this is really about played by being part of a group of technologies working together to give overall solutions
Allen Hall: because the robot’s not that big.
It could be taken up tower relatively easily, put on the root of the blade, told to walk around it. You gotta scan now, you know. It’s a lot easier than trying to put a technician on ropes out there for sure.
Chris Cieslak: Yeah.
Allen Hall: And the speed up it.
Joel Saxum: So let’s talk about execution then for a second. When that goes to the field from you, someone says, Chris needs some help, what does it look like?
How does it work?
Chris Cieslak: Once we get a call out, um, we’ll do a site assessment. We’ve got all our rams, everything in place. You know, we’ve been on turbines. We know the process of getting out there. We’re all GWO qualified and go to site and do their work. Um, for us, we can [00:13:00] turn up on site, unload the van, the robot is on a blade in less than an hour.
Ready to inspect? Yep. Typically half an hour. You know, if we’ve been on that same turbine a number of times, it’s somewhere just like clockwork. You know, muscle memory comes in, you’ve got all those processes down, um, and then it’s just scanning. Our robot operator just presses a button and we just watch it perform scans.
And as I said, you know, we are not necessarily the NDT experts. We obviously are very mindful of NDT and know what scans look like. But if there’s any issues, we have a styling, we dial in remote to our supplement expert, they can actually remotely take control, change the settings, parameters.
Allen Hall: Wow.
Chris Cieslak: And so they’re virtually present and that’s one of the beauties, you know, you don’t need to have people on site.
You can have our general, um, robot techs to do the work, but you still have that comfort of knowing that the data is being overlooked if need be by those experts.
Joel Saxum: The next level, um, commercial evolution would be being able to lease the kit to someone and or have ISPs do it for [00:14:00] you guys kinda globally, or what is the thought
Chris Cieslak: there?
Absolutely. So. Yeah, so we to, to really roll this out, we just wanna have people operate in the robots as if it’s like a drone. So drone inspection companies are a classic company that we see perfectly aligned with. You’ve got the sky specs of this world, you know, you’ve got drone operator, they do a scan, they can find something, put the robot up there and get that next level of information always straight away and feed that into their systems to give that insight into that customer.
Um, you know, be it an OEM who’s got a small service team, they can all be trained up. You’ve got general turbine technicians. They’ve all got G We working at height. That’s all you need to operate the bay by road, but you don’t need to have the RAA level qualified people, which are in short supply anyway.
Let them do the jobs that we are not gonna solve. They can do the big repairs we are taking away, you know, another problem for them, but giving them insights that make their job easier and more successful by removing any of those surprises when they’re gonna do that work.
Allen Hall: So what’s the plans for 2026 then?
Chris Cieslak: 2026 for us is to pick up where 2025 should have ended. [00:15:00] So we were, we were meant to be in the States. Yeah. On some projects that got postponed until 26. So it’s really, for us North America is, um, what we’re really, as you said, there’s seven, 5,000 turbines there, but there’s also a lot of, um, turbines with known issues that we can help determine which blades are affected.
And that involves blades on the ground, that involves blades, uh, that are flying. So. For us, we wanna get out to the states as soon as possible, so we’re working with some of the OEMs and, and essentially some of the asset owners.
Allen Hall: Chris, it’s so great to meet you in person and talk about the latest that’s happening.
Thank you. With Blade Bug, if people need to get ahold of you or Blade Bug, how do they do that?
Chris Cieslak: I, I would say LinkedIn is probably the best place to find myself and also Blade Bug and contact us, um, through that.
Allen Hall: Alright, great. Thanks Chris for joining us and we will see you at the next. So hopefully in America, come to America sometime.
We’d love to see you there.
Chris Cieslak: Thank you very [00:16:00] much.
Renewable Energy
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When I teach, I’m going for understanding of the topic, not the memorization of useless information.
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