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
IWTG Consulting on Pitch Bearing Cracks, Loose Root Inserts
Weather Guard Lightning Tech

IWTG Consulting on Pitch Bearing Cracks, Loose Root Inserts
Jon Zalar, founder of IWTG Consulting, joins to discuss broken blade bolts, cracked pitch bearings, loose root inserts, and early detection.
Sign up now for Uptime Tech News, our weekly newsletter on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on YouTube, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!
Welcome to Uptime Spotlight, shining light on wind energy’s brightest innovators. This is the progress powering tomorrow
Allen Hall: Jon, welcome back to the program.
Jon Zalar: Thanks for having me.
Allen Hall: Uh, last time I saw you, we were in Melbourne- Yep … at WOMA 2026, and that was a huge event. We know we’re gonna do it again next year in March three, the 3rd through the 5th, so you’re invited back, of course- I can’t wait … if you can make it. Yeah. Yeah.
It’s gonna be, it’s gonna be a good time. A lot is happening in the blade world and in the wind turbine world more broadly. A lot of things we’re hearing right now are related to blade bolt connection, pitch bearing inserts still. A lot of that still happening in the United States. What is the current status of, uh, the blade connection issues in the US?
I,
Jon Zalar: I feel like it’s a growing [00:01:00] issue, not super, super fast, but it seems to be getting a little worse. There’s, you know, more bolts breaking at that joint. Um, pitch bearing cracks are, seem to be pretty common. There’s different solutions for it, and then, you know, the root inserts are another thing that we’ve talked about before that seem to be happening more and more, or maybe more and more people are finding them ’cause they’re looking.
Allen Hall: What are the first indications that you have a blade bolt or some sort of joint issue at the root of a blade? What can you see?
Jon Zalar: A bolt laying in the hub bouncing around. Um, you know, from like a– looking at it from, like, the sensors on the turbine, it’s really hard to tell unless it gets really bad. Uh, some of the OEMs have some analytics developed to kinda start to indicate if there is a aero change because there’s missing bolts or root inserts are coming out, and they’re using that as a way to go figure out which ones to go inspect first.
Allen Hall: Really? Yeah. You think [00:02:00] the SCADA data will give you some indication that you have a, basically a little bit of a loose blade?
Jon Zalar: Yeah. I, I, I think because the number of turbines and the number of data points you have, I think there is a pretty good analytic out there right now.
Allen Hall: Wow. All right. I think a lot of our operators have not taken advantage of that.
Is, is that just b- based on the high-speed data, SCADA data, or is it low-speed data you could see that same effect?
Jon Zalar: I believe it’s on the low-speed data as well, but I bet the high-speed data was used to kinda develop it.
Allen Hall: Wow. All right. So that’s a huge help to operators. Yeah. So what are you looking for if you’re looking through SCADA data, what would be the couple of markers there that say, “Hey, maybe we ought to go look up at the– in the hub”?
Jon Zalar: I don’t know exactly what they’re using, but they would basically look for maybe an imbalance or looking for certain components that are being overworked.
Allen Hall: Oh, sure. Okay.
Jon Zalar: Yeah.
Allen Hall: So your pitch actuator may be getting a little bit overworked. It would seem like one of the places- I think that, yeah … that would get loaded, right?
Jon Zalar: Mm-hmm.
Allen Hall: Okay. [00:03:00] And any vibration monitoring going on? Because it, it, uh, in some cases you’re– I’m hearing, like, millimeter gaps-
Jon Zalar: Correct. Yeah …
Allen Hall: between the blade and the pitch bearing.
Jon Zalar: So probably a combination of the ALC sensors, at least on a GE turbine, looking at that. But the PCH box also is looking at the tower vibration, so it could be a combination of all three.
I don’t know the exact- Okay … details, but between all of that, I think there are some analytics that kinda say, “Hey, go take a look.” And then I think there’s some other companies that have- tools that go monitor it.
Allen Hall: Mm-hmm.
Jon Zalar: Dial indicators remotely or even, you know, people going up there with dial indicators to go kind of rotate the rotor and kind of see if there is gapping between the blade and the pitch bearing.
Allen Hall: Is that a safe situation in your– from the gapping? I’ve heard this where they’ve basically took shims and they’re trying to measure this gap or some sort of dial indication. Is that a smart thing to do? Is it even reliable to do it that way? [00:04:00]
Jon Zalar: I, I, I think there’s some reliability there. And like, you know, these are really big parts, right?
So like a little bit of gap, it, it’s probably expected to a point, but growing gaps is where you should be a little more scared.
Allen Hall: So you’re– you would have to go do that quarterly, monthly, weekly? How, how often would you have to do it to see the progression? Because I’ve heard stories of, uh, a couple of weeks from nothing to hub crack to, “Oh, it took a year or more.”
Jon Zalar: I think it depends on the issue. I think for– if you’re looking at that, the bolted joint itself between the root inserts and the, uh, bolts breaking itself, I, I think they’re doing about quarterly. Now, the pitch bearings inspections are also quarterly. They’re al- they’re, they’re leveraging the drone inspections for the blades, and they’re looking at the pitch bearings to see if they’re cracked, right?
Uh, you guys are doing that too.
Allen Hall: Okay.
Jon Zalar: I think Coraly is doing a good job mitigating the risk, feels like.
Allen Hall: Wow. All right. [00:05:00] Yolanda, looking at pitch bearings, you’ve looked at a lot of drone images in your lifetime. Mm-hmm. How much can you see on drone images on pitch bearings? Can you see cracks and, or y- or do you see grease, which is a really indication that something is wrong in the bearing?
Yolanda Padron: You can see grease. You can see the cracks pretty, pretty well. Yeah. The drone images are, are really high quality. Uh, but you did mention that it’s something that you’re seeing a lot more. Is it because there’s a lot more aging fleets, or is it a problem with a lot of the new turbines that are coming online?
Jon Zalar: I, I think it’s an, I think it’s a more of a fatigue problem, so the aging of the fleet. And also, I think more people are looking at it, right? ‘Cause, like, initially the drones that were looking for blade cracks weren’t looking at pitch bearings, but then pitch bearings started cracking, so now they added that to whatever they buy off the drone companies, right?
Go look at my pitch bearings, for example.
Allen Hall: Hmm.
Jon Zalar: So I, I think it’s a problem of the more you look sometimes, the more you find.
Yolanda Padron: Hmm.
Jon Zalar: Yeah.
Allen Hall: So we [00:06:00] have root insert issues, which are being addressed by a couple of different companies- Yes … uh, uh, with somewhat similar solutions. OEM is offering one right now also.
Jon Zalar: I, I think there’s three solutions. There’s two uptower that are basically looking at ways to go fill the void between the root insert itself and the blade root. Um, and I– there’s another company that’s also more of a downtower solution where they’re actually, like, r- drilling out the root inserts and putting new ones in that are gonna last better, longer.
Allen Hall: Okay. So the drilling out is, would be CNC onsite. Correct.
Jon Zalar: Yeah.
Allen Hall: And they’re based over in Europe. But th- the drilling out is a take the blade down, set it on the ground sort of- Yeah. Right … doing really fine machining on the, on the blade itself. So that, that’s a different, completely different insert that’s going into that-
Jon Zalar: Correct
Allen Hall: new hole or- Yep … clean hole, right? So it’s a, just a, uh, totally different kind of product versus trying to inject [00:07:00] some s- sort of epoxy or resin into the, the void.
Jon Zalar: Right. Yeah. Uh, I mean, you would prefer to do it uptower. It’s gonna cost you less money.
Allen Hall: Sure.
Jon Zalar: But you wanna make sure you do it right, so I think, uh, I do foresee it being a combination of both solutions kinda going forward.
Allen Hall: Is it dependent upon, like, how much damage has been already done, or what the fatigue w- uh, an estimate on what the fatigue life is?
Jon Zalar: I think it’s strictly on measurement perspective right now. So how much gapping you have, um, kinda determines what potential solutions you have.
Allen Hall: So the gaps aren’t big, right?
So the, the gaps I hear are one millimeter is k- kind of sort of start a problem.
Jon Zalar: Mm-hmm.
Allen Hall: Three millimeters is, “I need to be making decisions.”
Jon Zalar: Yeah. So- That, that’s what I’ve heard, too. Yes.
Allen Hall: Three millimeters is about a eighth of an inch.
Jon Zalar: Mm-hmm.
Allen Hall: So it’s not a lot of m-
Jon Zalar: But you can see sunlight through it if you’re s- down there.
Allen Hall: Okay. That’s not… Well, you should see. That’s not
Jon Zalar: good either. Yeah.
Allen Hall: Right. Okay. So in a, in a three millimeter situation then, you’re doing what? [00:08:00]
Jon Zalar: You’re trying to decide if the uptower solutions are something you wanna go try, ’cause they’re still in the trial mode from my understanding or-
Allen Hall: Okay …
Jon Zalar: people are learning a lot.
So I think when you get to that point, you’re calling some of those companies to say, “Hey, I have this issue. I got a couple blades with, you know, .3. Can you guy- you guys wanna come take a look at it, see if your solutions, if you guys wanna go use it or not?” And then I think the ones that get too bad, from my understanding right now, is they’re, they’re replacing the blades.
Allen Hall: So they’re taking the whole blade down.
Jon Zalar: Yes.
Allen Hall: And what’s the thought process in that? Uh, versus drilling out the inserts and putting new inserts in. Is there just a composite degradation that’s happened around those joints that it just puts it at risk or, or you have actually aged the blade much faster than you would otherwise have done?
Jon Zalar: I, I think they aged that particular connection too much. So I, I- Wow … either between the [00:09:00] fatigue or lack of epoxy resin, w- whatever the actual root cause is for that root insert coming out, when it gets that bad, it’s like you’re not gonna be able to inject enough To make it adhere
Allen Hall: You can’t de-age it.
Jon Zalar: Correct.
Allen Hall: Right?
Jon Zalar: Yeah.
Allen Hall: Bring back the youthfulness of the blade. Wow. All right. And we have seen this worldwide. I know in the, in the States you hear about it all the time, but it, this seems to be not a US- Correct … problem.
Jon Zalar: It’s a worldwide problem, yes.
Allen Hall: Okay. So if, if it’s a worldwide problem, are there more solutions on the way?
I know you talked about three of them already.
Jon Zalar: I have not heard of any other ones except those three as of today.
Allen Hall: Wow.
Jon Zalar: There could be other people working on it. I think there should be.
Allen Hall: So, yeah. You would think so, yeah. So we’ll, I guess we’ll eventually hear about it on the podcast. Usually people with technology will contact us.
They might call,
Jon Zalar: yeah. They might call you, they might call you tomorrow.
Allen Hall: Sure, they may. So that leads to sort of a subsequent issue, which I think is getting grouped together. So the [00:10:00] hub crack, pitch bearing crack, root insert pullout issue is also discussed with blade bolts being broken.
Jon Zalar: Correct.
Allen Hall: Are they related or are they separate engineering problems?
Jon Zalar: If you look at them individually, you’d probably come up with some separate answers, but if you combine them all together, you kind of start looking at is there too much loading happening in the leading and trailing edge of the blade? ‘Cause the hub cracks, the root inserts, and the blade bolts, from my understanding, are happening at those two highly loaded areas of the, the blade or that whole rotor connection.
So I mean, I do feel the root cause is probably a little higher loads than anticipated.
Allen Hall: I think everybody’s talked about when they’ve done the injection method and the drilling method, all they’re discussing is leading edge, trailing edge.
Jon Zalar: Yes.
Allen Hall: And how– It’s a question of how many- Correct … are you gonna replace.
So th- [00:11:00] that’s, those are the two highly loaded spots on the bolted connection.
Jon Zalar: Correct.
Allen Hall: And that’s where blade bolts are also breaking or, or the bolts breaking elsewhere around the periphery?
Jon Zalar: I don’t have all the data, but what I had seen, it’s very similar areas.
Allen Hall: So if you don’t pull the insert out, you’re then loading the bolt.
Cr- Right It’s one or the other, right? Right. Yeah. So the, the, the load path is the load path, so it’s coming through the insert into the bolt. Bolt’s carrying it into the pitch bearing. Pitch bearing’s carrying it into the hub.
Jon Zalar: Correct.
Allen Hall: Hub carrying it downtower. So eventually, one of those, uh, links in the chain is- The weakest.
Yeah … is, is the le- is the weakest. What is it about blade bolts that is so dangerous? We hear– we walk onsite to an O&M building, there are signs saying, you know, “Pay attention for loose bolts. Look around on the ground for loose bolts.” We’re gonna– and as electrical engineer, like, “Whoa.” Bolts should not be falling out of this tower.
What i- what is that sort of sequence where a [00:12:00] bolt would escape from the nacelle?
Jon Zalar: So let’s just use one bolt. One bolt breaks, falls in the hub, bouncing around, doing some– potentially doing some damage inside the hub. And ’cause these turbines, you don’t need to go out there every day ’cause they do run pretty good, right?
Right. You just do your regular maintenance. And if you don’t really know about that, ’cause, like, it bounces around for a while, then it usually gets, like, lodged behind a, uh, either center box or pitch cabinet or actually in the front sometimes. Kinda don’t know it happened. But, you know, frees itself up, keeps bouncing around, it, it could escape through the hatch covers ’cause, you know, people have to get into the hub anyway.
And I’m sure a lot of people listening here that have sites, like, you know, probably found some bolts laying on the ground, which is a little scary.
Allen Hall: Right. So is, is the busting the hatch opening levers? I know there, there’s a couple different ways to get into that hatch. Yeah. But, uh, is it just completely busting the hatch?
Yeah. So it’s– [00:13:00] okay. So you see a– so if you see a loose hatch panel, you have an issue. You probably gotta be careful about coming up on that turbine?
Jon Zalar: Potentially. A lot, a lot of hatches are, you know, not always maintained well.
Allen Hall: Right. I’ve seen them, I’ve seen loose ones, yeah.
Jon Zalar: Yeah.
Allen Hall: Okay. So that, that would be a sign that– but though if, if you’re approaching a turbine, one look on the ground.
And Yolando, you, you’ve seen a lot of turbines. So are you, are we looking on the ground and seeing what’s around the turbine before we approach the turbine now? Yeah. Just, just a sanity check?
Yolanda Padron: Yeah. Be aware also of what’s happening on site, right? Because if it’s some- if it’s a problem on site, you need to be extra careful when you’re approaching any turbine there.
Uh, is it something that people maybe should start thinking about implementing, like, a sensors earlier on than when they’re seeing the issue actually happen?
Jon Zalar: Yeah. I, I, I think that’s a potential, ’cause it, the quicker you catch it, the less damage you’re gonna do, and it also reduce the risk of [00:14:00] it, um, falling out of the hub And I’ve worked with a couple of my, uh, customers for some, like, potential ways to detect it.
Still kind of trialing it right now. But I, I do think there’s gonna be some benefit from a safety reduction, but also from a strictly a damage. ‘Cause, like, you get a couple bolts bouncing around there, and you bang up some cabinets or some pitch motors, that’s expensive and hard to go fix.
Yolanda Padron: Yeah, we were talking about it earlier too.
Like, it goes down, it can hit a transformer, it can hit, like, a truck or someone.
Jon Zalar: Chance of it hitting someone. Yeah. I mean, I don’t care what hard hat you have on, it’s not gonna do anything.
Yolanda Padron: Yeah.
Allen Hall: So what kind of sensor should you be putting onto the turbine if you don’t have access to the SCADA data or you don’t know what the correct algorithm is to suss out there’s something wrong up there?
But a, a bolt breaking is not gonna be something that a SCADA would even pick up, I don’t think. One bolt out of the whole- Yeah. No.
Jon Zalar: No way. Okay. I mean, there’s a– I think there’s, like, [00:15:00]one company looking at more of a, like, mechanical way to, like, prevent the bolt from coming out. I forgot the name of it.
Allen Hall: Okay.
Jon Zalar: Um, and then what I was looking at was more of a, like, you know, microphone type detection to kind of listen for that.
Allen Hall: It would make a lot of noise.
Jon Zalar: Yeah. It seems like it works. It, um, yeah, still more development needed on my end.
Allen Hall: So- The engineer in me was, is saying, “Why are we not putting strain gauges on bolts?”
I picked on the leading and the trailing. It’s like right dead center there to look at, even if it’s just two strain gauge bolts to see what the loads are.
Jon Zalar: So like there are s- there are bolts that are, or that are made with the strain gauges built in that you can use to go, you know, monitor that. But you also need to understand like what was the design intent.
So unless you’re working with the OEM, you don’t really know what you’re seeing is good or bad. You just say, “Oh-
Allen Hall: You just see a number.
Jon Zalar: Yeah. Right. I mean like, and if you install, I don’t know, four, you’d be like, “All right. Leading and trailing edge are higher [00:16:00] than the other two.” Well, yeah, it’s supposed to be, but like is a 10% difference expected or not expected?
Allen Hall: Is that something where if you’re, especially if you’re in a full service agreement, and a lot of these turbines are- Yeah … for the first couple of years, if you were to do that, it’s something you would just say to the OEM, “Hey, this is, these are the loads we’re seeing from the strain gauges on these bolts.
Does this make sense to you?” Or, or would an OEM just not even respond to that kind of inquiry?
Jon Zalar: I mean, I think it’s all about relationship with the OEM. I, I, I think
Allen Hall: it- I think they would wanna know.
Jon Zalar: I have a feeling they probably are looking.
Allen Hall: Okay.
Jon Zalar: I mean, ’cause I mean they have the test turbines too that they probab- that, that I know they have instrumented heavily.
Allen Hall: Yeah. So they, they’re probably getting at least some feedback. Th- that’s the problem. Yeah. And you worked on the other side, right? I have. So you worked for an OEM doing the RTAs. The first problem is you don’t have data, so now you gotta go get the data.
Jon Zalar: Correct.
Allen Hall: And that data is not available tomorrow. No.
‘Cause you’re gonna have to go run some sort of design of experiment to go figure out if [00:17:00] there is even a true problem or even what the root causes could be.
Jon Zalar: And it, and it’s expensive to go instrument a blade and get the data back at the right speed and connected to the turbine data. I mean, I rem- I, I used to say it’s about like 300 to 500,000 to go put a couple gauges on a blade just with all the equipment you need to get the data correct.
Allen Hall: To get the right data.
Jon Zalar: Get the right data at the right frequency connected to the controller. It’s, it’s very expensive.
Allen Hall: Wow. Okay. Yeah. I, I don’t, I don’t see a lot of operators doing that.
Jon Zalar: And especially connecting it to the operating data, right? So like if you go put a strain gauge and I don’t know, you’re curtailed, you’re only making, I don’t know, a megawatt- Doesn’t matter.
And if you don’t know what the turbine’s doing and you’re looking at this, like, strain gauge data, it’s really hard to correlate anything.
Allen Hall: So you need a full suite of data. Yeah. That includes weather data- Yeah … at some level, right? Gust winds and- Oh,
Jon Zalar: yeah …
Allen Hall: average wind speed. You need the anemometer. You need which, which way [00:18:00] the n- cell’s pointing.
Y- uh, you would need a lot of information- And what the controller’s- … to even suss it out …
Jon Zalar: and what the controller’s doing, right? Right. ‘Cause, like, every turbine, the controller’s trying to, like, you know, balance the rotor the whole time. It’s trying to, you know, micro pitch depending on what the winds are doing.
And if you don’t know what all that stuff’s doing, like, it’s really hard to correlate a strain gauge measurement to is that bad or not.
Allen Hall: It’s a complicated problem.
Jon Zalar: Yes. That’s why RCAs take, you know, a long time, and they’re not done in two weeks.
Allen Hall: No, they’re done in a year.
Jon Zalar: Yeah.
Allen Hall: Typically, or longer. So what should an operator be thinking about now?
If, if we s- get our drone images back, we’re scanning through them like, “Oh, there’s a crack” What am I doing next besides calling you and connecting to your LinkedIn page?
Jon Zalar: So right now with the pitch bearing crack, um, some of the OEMs are providing stiffener plates to put over the crack and try to run it.
Allen Hall: So that’s a doubler plate, basically. A double plate. Doubler
Jon Zalar: plate, yes. [00:19:00]
Allen Hall: Yeah. Okay. So even in a, in a crack scenario, that pitch bearing, if given mechanical support, can run like that?
Jon Zalar: That’s my understanding, yes. That, that potentially could run for some period of time. I don’t know if it’ll make it 20 years or not, but it’ll buy you time for sure.
Allen Hall: Does that involve a crane to do that work or is that just… My recollection, that was in pieces, like there, it’s not a ring, it’s a, a couple of pieces that you’d be able to bolt on without taking the-
Jon Zalar: No, it’s a- … blade down … it’s a, it’s a single piece that-
Allen Hall: It’s like a single casting kind of thing.
Jon Zalar: Right. And I, I think you need some like small crane, like a jig crane or one of those-
Allen Hall: Just to support the blade while you do it?
Jon Zalar: And to go put it in, right. Okay. Yeah, I don’t think, you’re not taking the blade off. You’re not taking the
Allen Hall: blade down.
Jon Zalar: Correct. Yeah. It’s, it’s done with the blade up there.
Allen Hall: Okay.
Jon Zalar: You’re putting new, putting longer studs in and putting the plate on.
Allen Hall: So first step is let’s get the joint reinforced. Right.
That’s the easy first step.
Jon Zalar: Right. Although there has been some cases where since [00:20:00]you’ve put that stiffener plate on, the loads get spread out to the end of the plate, and then you- Sure … you could see cracks there.
Allen Hall: Okay. All right. So the loads- It, that- … have to go somewhere …
Jon Zalar: loads have to go somewhere. That’s, that is a bottom line.
Allen Hall: All right. So you’re just changing where the load path is, so you have to be cognizant of that. Okay. Sure. Fine. But if you have, uh, especially in the United States, you don’t have 10 of these turbines, you have 50, 100- 100 … 200, 300 of these things, or thousands as it, as it turns out. Are there simple solutions that can be applied to, just to give me a sense, like that turbine’s having a problem, but the one next to it’s not, and, and just, just from a maintenance spin standpoint where I’m not just blanketing everything and trying to do everything to all these turbines at once, how do I, how do I manage this?
Jon Zalar: I, I think it’s like being very observant. So like, you know, making sure you’re looking at the pitch bearings from the drone images, right? Um, also talking [00:21:00] to your maintenance people like, “Hey, are, are you finding a bunch of broken bolts? Like, what positions?” Like, you know, if I was back at the OEM, I would like to have as much data as possible on this issue.
Like how many bolts are, when did you find them, what positions? A lot of times we, when I was there, like we would not get all that information, so it’s like really hard to run an RCA without that information.
Allen Hall: Sure. Yeah, where did this bolt break in the ring?
Jon Zalar: Right.
Allen Hall: Could tell you a lot. Is it just a b- bad lot of bolts, or is it something more load related?
Jon Zalar: Correct.
Allen Hall: Wow. Okay.
Yolanda Padron: Yeah, I think that’s a really good point, too, to make sure that you’re connected with like every stage of the operations. ‘Cause I know that everybody’s obviously really, really busy on a wind farm, but it’s really common for like an engineer to have certain data and the site team to just be running around and having a lot of data, but maybe they don’t realize that, oh, it’s important to know how many bolts per tower are coming down.
Jon Zalar: Correct. Yeah
Allen Hall: That’s a lot of work
Jon Zalar: It definitely-
Allen Hall: It’s a tremendous effort if you’re gonna [00:22:00] go after this problem and, and solve it RCS
Jon Zalar: are hard. They
Allen Hall: are. Yeah. All of it. Yeah. Machines are complicated today. There’s a lot of computer-driven s- things about them, and then you have these loading issues, and you have composite materials.
Th- there’s just, y-
Jon Zalar: you got to get- It’s a very complex
Allen Hall: It’s a machine, right? Yeah. It’s a complex machine. So how do people reach out to… You’re, you’re the head of IWTG, which is based in South Carolina, but you do consulting worldwide. Yes. And, and you are a huge resource because you understand the complexities of these problems.
How do people get ahold of you and, and get something started if they have a, a, a blade bolt issue or an insert issue or a cracked pitch bearing? Where do they start?
Jon Zalar: They can send me an email, jzalar@iwtgconsulting.com.
Allen Hall: Okay. And you have a great LinkedIn page, so you can connect with you on LinkedIn.
Jon Zalar: Yes.
Yeah, I have one
Allen Hall: of those. Yes. Or you could just come to WOMA in [00:23:00]2027. Yeah. You can. You can meet John there and, and arrange everything there. So John, it’s great to see you, and thank you for coming up. We, uh, we’re recording this at the world headquarters of Weather Guard Lightning Tech, and, uh, John just lives down the street in, in, in US terms.
Yeah. So it’s, it’s great to have John come and visit us up here in North Carolina. So John, thank you so much for joining us.
Jon Zalar: Thanks for having me. Appreciate it.
Renewable Energy
The Divided States of America
Trump’s (fairly successful) attempts to divide America are just a means to the end of staying in power so as to be able to continue to loot the U.S. treasury.
At this point, there are three essential factions in the United States:
- A small number of extremely powerful billionaires
- The MAGA base of white nationalist / hateful morons who believe that only Trump can save us from communism, racial impurity, and godlessness
- Decent, educated people
Renewable Energy
Faith and Reason
People have been dancing around the faith/reason duality for more than 2000 years. Aristotle worked out the rules of logic around 350 BCE, and Thomas Aquinas assumed the task of using them to prove the existence of God in the 13th Century CE. Descartes came along a couple of hundred years later, and made some improvements on all this, but we’re still left with very little.
As I told my nephew once when he was assigned a college paper on this, “You can’t have your metaphysical cake and eat it too. You either believe in things for which there is evidence, or you don’t.”
Moreover, as shown at left, faith runs headlong into logical inconsistencies.
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