Weather Guard Lightning Tech

NSK’s Super-TF Main Bearing Solution
You may have missed this fantastic with Loren Walton from NSK, so we’re sharing it again. He discusses the challenges of main shaft bearing failures in wind turbines and NSK’s Super-TF bearing technology as a durable solution. Loren also covers the limitations of previous diamond-like carbon coatings and how NSK’s advanced heat-treated steel can improve turbine longevity.
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Sign up now for Uptime Tech News, our weekly email update on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on Facebook, YouTube, Twitter, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary Barnes’ YouTube channel here. Have a question we can answer on the show? Email us!
Allen Hall: With modern wind turbines growing larger and main shaft bearings failing prematurely. The industry needs innovative solutions rather than relying on yesterday’s technology. This week we speak with Loren Walton, manager of corporate accounts at NSK. NSK has developed super tough bearing technology, a special heat treated steel that creates a significantly harder surface without coatings delivering long lifespans and eliminating catastrophic failures in today’s larger wind turbines.
Welcome to Uptime Spotlight, shining Light on Wind. Energy’s brightest innovators. This is the progress powering tomorrow.
Allen Hall: Loren, welcome to the show. Thanks for having me. Appreciate your time today. Loren, we brought you in the program because you’re an expert in bearings. You’re with NSK, A lot of knowledge, a lot of history there. First, I want to ask a real simple question because we’ve run into operators all across the United States and the world.
Generally speaking, we just got back from Australia who are having problems with main shaft bearings. And maybe the first thing to do here is to describe what some of the problems are that operators are facing with the traditional main shaft bearings. Yeah. So
Loren Walton: traditionally what we were saying was a whole lot of, I guess I’ll say combined loading, right? So it’s a, radio load that is, up and down and some axial thrust that’s coming in from the wind shear, right? So combining the weight of the main shaft, which is you’re taking up from that radio load with that wind shear. So then you end up having some combined loading where.
The downed wind row is seeing a little bit more of load share than the upwind row. That’s getting through the lubricant regime, which is then creating some micro welding and shearing, any amount of metal, any steel. When it’s created, it’s going to have some disparities. I use my fingers as the disparities, right?
So your roller, your raceway, or your raceway, your roller. There’s gonna be some welding and shearing that happens when that is under high pressure. And so your lubricant is supposed to create a little bit of a gap between those. When you don’t have that gap you end up with the welding and shearing, you end up with what we call peeling damage, and then that peeling basically goes over and over again, and you start having high levels of debris.
Inside of the system. And then once that debris starts going all bets are off, right? ’cause you can’t really even model debris very linearly. It just goes into additional sping and then you end up, if you keep letting it run, you end up with a through crack inside of one of your components, which is typically your inner ring.
’cause it’s press fit on the shaft.
Joel Saxum: And a important concept here as well is because main bearings are basically a sealed lubricant system. There isn’t filters on these, right? So like when you start to get debris moving around in the system, it stays there. It just, it’s not oh, let’s go change oil on this thing.
And we remove the debris, we put a new filter on it, we’re good to go. It’s not, it’s just, it’s in that system now. If it, because it’s a closed loop basically, right? Correct. Yeah. So the grease shift is in there,
Loren Walton: there is an opportunity for you to have, replenishment, right? So you can put new grease in so that old grease comes out.
But even then, you’re reliant on gravity and whatever you can get out of the system. You’re hoping that as you put new grease in, old grease comes out. But depending on how long you’ve been running, it is very possible too that you might end up putting new grease in and new grease out, right?
Because the old grease is so stuck in there. Is now hard to move. It’s very difficult to get that old grease to actually come out. So depending on, if you have maybe a auto lube system or something like that, it might be, you might be running that grease a little bit more consistently.
Otherwise, yeah. You’re stuck with what you’re stuck with once that debris gets going.
Allen Hall: So what you’re saying is as the weight of the shaft and the rotors, everything has gone up on basically two and a half megawatts seems to be that critical area. And above that, depending upon the bearing design, the coatings or the finishes combined with the lubricants, you can actually, or what is happening is we’re micro welding the bearings together because of the weight and the, just the the friction that’s between those two things that.
I don’t think anybody from the technical side realizes it’s happening. It’s not something you think about in a bearing. That gets me into the next question of obviously the bearing manufacturers try to treat the bearings some way to prevent that from happening. It seems like diamond, like carbon coatings were the solution a couple of years ago.
Why was that chosen? Why did that thought process happen? Is that something that was successful previously on smaller turbines and was this implemented on the larger turbines or what was the engineering behind that?
Loren Walton: Yeah, so I started my career in the when generation space in bearings somewhere around 2011.
And at that time, that was when. We were moving from the kilowatt class to the megawatt class turbines. And that was when we first started seeing a whole lot of main shaft bearing problems. And it is all the stuff that I just described, right? The micro welding the micro welding, macro micro pitting, leading the macro pitting, leading the sping, all that stuff, right?
So that was something that was very prominent once you started going from that kilowatt class to that megawatt class and to combat that. DLC was introduced and the thought there was you have a dissimilar material. So what I just described is that, again, I’ll bring my disparities back that micro welding happening, that welding and shearing.
That only happens because you have two of the same like materials. That doesn’t happen if you have a dissimilar material. So DLC di like carving. So what you have is an amorphous tsin carbide that you adhere to the surface of one of those components. So in this case, the roller is what you adhere, the amorphous tsin carbide too.
So that was a game changer. That was huge, right? We went from a few years of life, maybe on average three to five. To I remember seeing a report where A DOC bearing came out after 10 years and still looked beautiful. It was, sorry I like bearing, so I use terminology like beautiful, right?
That I don’t know if that I caught myself after I said the word beautiful for bearing, but that’s just, bear with me. So when we were doing inspections on some turbines that were greater than two megawatt we found. Some abnormalities, we’ll say, in some of our inspections, we didn’t expect to see certain things that we started to see.
We started to see more issues on the inner ring instead of the outer ring, we started to see more issues on rollers than we had seen before. And these were on coating rollers, right? So somebody had already gone to the solution of DLC because it had worked before. And in this case, the customer we were working with.
They actually shortened their life. They went from four years of operation to two years of operation on average when they were using a product that had the coating on it. So again, an abnormality, something that we weren’t used to seeing. So we did all of our investigations, all of the inspections that we normally run through.
We saw that there was actually damage to the DLC. There was the DOC was being harmed. We saw that there was also subsurface wide edge area, wide edge cracking that was also in, in the inner ring and in the rollers. So then we saw that when you compare the uncoated to the coated, the once the DOC was harmed, now you have actually an accelerant to failure.
It. It wasn’t that the DOC was wrong, there was nothing wrong with the DOC. But once it was harmed, you had an accelerant to failure. So instead of it lasting about four years, you’re saying it lasted two years.
Joel Saxum: When you have starting to have a failure with DLC, what are the things that an operator should be looking for, whether it’s a, the DLC ones, because they’re very common right now.
The, in the say the US fleet, there is a ton of DLC coded bearings out there. What are things that an operator should be looking for to see a failure before it turns into a really big problem?
Loren Walton: Yeah, so you’ll primarily see some amount of vibration signatures in your rollers is what I’ve understood from some of the people that I’ve talked to.
It’s really hard to see though, I think. I think that is still getting, like people are still getting better and better at identifying it. Unfortunately, in a lot of cases, what you have to do is see. If you have to look backward on your vibration to see, okay, this was the point because in a number of cases, you might look on Monday, let’s say you see it on vibration, you go do a physical inspection and the rollers look fine.
Finding damage to DOC is not typically something that you can easily catch with the eye. When you’re doing a physical inspection, you’re limited on how many rollers you can check. You’re limited on. What you can actually see. There’s strong limitations there. I don’t fault anyone, if you’re, if you end up with a bearing that blows up because you had a catastrophic roller failure, that isn’t usually something that you can quickly catch unless have learned what the signature looks like from your vibration.
For us, the way we see it is a little, we cheat, right? We have a scanning electron microscope. Where we can see the damage, we can see it almost looks like fractured glass. If you can think of when maybe something hits your windshield and it shatters, right? It looks like that for us under the microscope.
So we can see the damage to the DLC, we can see where there’s maybe some sort of a slit or something like that on the coating. So that’s easy for us to find because we’re. Checking it after it’s already out.
Joel Saxum: There was a certain time, right? It went from the kilowatt class, then we started putting DLC in and then we got a little bit bigger, and then the DLC started to fail.
In between that one and two megawatt class, it worked really well. And maybe that’s the, is it the weight of the rotors or like why did it, why is it starting DLC starting to fail now in these larger rotors, in your opinion?
Loren Walton: For as a bearing manufacturer? We have to adjust to whatever is thrown our way, right?
So I, I don’t get to change anything about the application. I am told this is the application, this is what’s failing. Make it better, please. So that’s the constraint that I’m left. You play the car as you do, right? I can’t ask for a reshow. There’s a lot of investigation that’s happening.
I think that there’s a number of different. Things that are happening. I think people were looking for one smoking gun, but I think we’re more so standing in front of a brigade. I don’t think that there is one. I think there’s a bunch of them. That there’s things like, as the turbine gets larger now, the angles are changing on what is, what was the plane of where the bearing was sitting.
The angles are now changing. You have the aspect of people are seeing that there’s more current that’s going through that, that they weren’t finding before. But even you can’t discount the part of the rotor size today. I think that there is still a multitude of different. Problems that we’re addressing, but the biggest one that I see is that we know that the DLC is being harmed.
So we have to address that because that is the biggest, known right now. I think we have to be willing to change what was the mindset before that. DLC is the solution to everything. And we have to change that to, we have to come up with solutions that are agnostic to the coating that are just.
Able to still combat that peeling damage without needing the coating to be the way to to solve it.
Allen Hall: Yeah, that’s a really interesting way to look at it. At some point you just go, it doesn’t matter why it’s failing. We need to move on to some other technology and. NSK has a lot of bearing knowledge and treatments, and the one I’ve seen for main bearings more recent, most recently is what you guys call super tough.
It’s not a coating, it’s a heat treatment, but it’s unique. Can you describe what that treatment is and why it is so effective in these two megawatt machines?
Loren Walton: So super tough is a medium carbon base steel with varying alloy elements that gives it some different properties and then it’s heat treated.
It’s a cargo nitrite, heat treatment that then leaves the surface significantly hard while having a a mediumly softer core. That’s a bunch of words. I’ll go into a little bit more of what that means. There’s different parts of why that is important, right? So we talked about peeling damage, we talked about the disparity contacts.
We talked about some of that already. The important thing to think through on that is if you look at the matrix of the skin of a steel component, they’re made up of something called carbides. Carbides are basically the hard parts that the bearing runs on. If you have those carbides organized in a very fine and uniform dispersion, you now have uniform wear.
If those are also very hard, they also now I guess push against each other in a stronger way as opposed to. Welding to each other like we described before. So a harder surface is harder to have a welding and shearing than a softer surface. Super tough. It leaves a significantly hard surface, harder than other I’ll call ’em competing.
Technologies, whether it’s a through hard or a case car rise significantly harder than both of those. And we lead with super tough because of the peeling damage that it combats super tough. Was created originally four applications similar to main shaft, where it was slow speed. It was high low.
There was the debris, but typically the debris was coming from the outside in. In the case of main shaft, typically the debris is created by its own bearing. The bearing is eating itself alive, right? It’s from the inside out. And yeah, super tough is got a number of different characteristics that we like.
And to be honest for NSK, for material, that’s one of our core competencies. Super tough wasn’t the only option for us to choose, but it’s the one that made the most sense. We had a few other choices that we could have gone with. We have other materials that we use for slow speeds and high lows and applications like steel making and things like that.
For the size of the shafts. For the operations, it made the most sense to use Super tough.
Joel Saxum: This isn’t something that you engineered for win. This is something that you’ve adapted to win because you have a track record of using it in other places as well. What other, like from an NSK standpoint, what other kind of bearing applications do you use?
Super tough in just to to understand. The track record of it, it was created for,
Loren Walton: Like I said, steel making was one of the big places where we use the NSK as a Japanese company. Steel is manufactured heavily in Japan. Japan is known for steel. Other places where we would use it would be like paper mining, heavy industries basically, where we would use super tough wherever there was a situation where we needed a combination of.
High loading and ability to combat any amount of debris that’s being put into the system. So it was introduced into wind, actually, I wanna say in gearbox because there was some other things that we saw that actually you could combat. Why X area and YX cracking. So actually I should probably take a step back and say from when we were doing our inspections and we saw that the DOC was being harmed, and I mentioned that we also saw a wide edge area and wide edge cracking inside of the inner ring and the rollers.
Another reason that we used super tough as the way to combat was because we had already had success with using super tough to combat wide edge cracking. So when we started seeing it in main shaft, in addition to having the ability to combat the peeling damage. Also when we started seeing why that area in main shaft, another reason that it made sense to go away from just standard through hard, going into the super tough.
And
Allen Hall: as we talk to operators across the United States at the moment that have DLC throughout their turbines farms you get a lot of worried looks and. Until we had talked to you and to Corey MIT lighter, we did not have any suggestions. And now that we’re talking with you here NSK seems like an obvious choice.
How do operators start to implement the super tough design into their turbines? What does that look like? Can they, how fast is a swap out? Do they need to do a lot of engineering ahead of time? What does that process look like?
Loren Walton: Yeah, so the bearings that we’re offering are the same construction, right?
So it’s a. Spherical roller bearing same IDOD. With that, the OEM design had it with it there shouldn’t be any sort of retrofitting or changing of anything required. Honestly, the biggest thing is I think for most people, understanding that we are making changes from the inside out is the biggest thing to understand, right?
Because if we look at one shiny round object and another shiny round object. And one of them has black rollers and you say yeah, that one looks like it’s different. Or one has a change to contact angle. Yeah, that one looks like it’s different. It’s a little bit harder to see, yeah, we make some changes to the internal geometry, but you can’t see it.
Or we made changes to the material and the heat treat, but you can’t see that. So we are, usually having to educate. What you are not seeing is what you’re getting from us, right? It’s all of the information, it’s all of the gathering, it’s all of the inspections. And then knowing that we can combat that with a different approach than what was used previously.
So everything for installation is exactly
Allen Hall: the same. Alright, so if an operator wants to start working with NSK, and it sounds like they probably should start talking to you, Loren, because you’re a wealth of information and you can help them out greatly speed up this process to get the DLC bearings off of their turbines and get running again before they have really big problems.
How do they do that? How do they get ahold of you? You, Loren? How do they get ahold of NSK? Where should they go?
Loren Walton: Yeah, so I guess I hope that they listen to this podcast and then we are visible, right? We attend all of the major events, right? I just came from presenting at the Drivetrain Reliability Collaborative LA this week week after next I’ll be at the operation Maintenance Safety conference for a CP.
I’ll also be at Clean Power in Phoenix. I typically go to all three of those conferences every year. But it’s not just me, right? We also have a team of engineers and segment personnel that work and win. But if you’re specifically looking for me I guess I can give out my email address.
It’s my, my last name Walton, W-A-O-T-O-N, and then my first initial L and that’s at. k.com. So Walton l@nskcorp.com. So you could email me at any time, always looking for the next science fair project to work on, and you need to go
Allen Hall: to nsk.com and check out the website. There is a great deal of information about wind turbine bearing specifically.
Really informative videos to go along with it. You can see the super tough coding and all the details there on the website, and you obviously you can connect with Loren on LinkedIn. He’s available there too, so reach out to Loren. Loren, thank you so much for being on the podcast. Learned a great deal today.
We need you to come back and talk bearing some more.
Loren Walton: Yes. Yes. Appreciate it.
https://weatherguardwind.com/nsk-super-tf-main-bearings-2/
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Rosemary previews Pardalote’s new hands-on blade repair course. EverWind’s Ocean Lake, Canada’s largest wind project, will feed a green hydrogen and ammonia plant in Nova Scotia rather than the grid. Plus BP’s exit from an offshore project in Japan, and the wake-effect lawsuit pitting SSE, Equinor, and Vårgrønn against RWE’s Dogger Bank South.
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!
The Uptime Wind Energy podcast, brought to you by StrikeTape. Protecting thousands of wind turbines from lightning damage worldwide. Visit striketape.com. And now your hosts
Allen Hall 2025: Welcome to the Uptime Wind Energy podcast. I’m your host, Allen Hall. I’m here with Matthew Stead, Yolanda Padron, and Rosemary Barnes is back this week.
Rosemary, you’ve been to a number of training courses over the last couple of weeks. The first off was GWO. What was your experience at GWO training?
Rosemary1: It was the fourth or maybe even fifth time that I’ve done it. Um, I did it a few times in Denmark and then, uh, this is the second time doing it in Australia. also, this was my first time doing first aid in Australia. Last time they did GWO here, but my first aid was still valid from Europe, so I, I didn’t redo it. And it’s like so much about [00:01:00] snakes and spiders and jellyfish But a good, good rule of thumb, not 100% accurate, but good rule of thumb, if it is something from the ocean that stung you, then you put something warm on it, and if it’s something from the land that stung or bit you, then something cold on it,
Allen Hall 2025: well, how often do you usually take GWO training?
Rosemary1: You gotta do it every two years to be valid. I don’t do it every two years because, um, if you do it every two years, like within two years, then you can do the refresher course. So that’s three days instead of four However, um, because I don’t climb constantly, like often it will be six months or more in between climbs, I’ll just do it before I know that I’ve got a climb.
all the other people except for one were technicians who, you know, have been working for a while.
So they’re also doing the full course, not the refresher. So they get a little bit more practice than I do. But, um, it’s just not often enough. Y-you know, like every time I go it’s like I, I really feel the need to have the refresher, um, because I’m just not fully on top of it. ‘Cause it’s [00:02:00] not just that you need to know what to do. You need to be able to… Like if you need to use it, you’re gonna be freaking out, you know?
This is the worst thing that’s probably ever happened in your life, and now you’ve gotta remember all your training. It’s like you want it to be actually second nature to some extent. So yeah, first day is manual handling, which is v- you know, very– That one’s very easy and I would be happy to never do that again.
Like I will always remember that. Um, then you got fire, um, fire safety awareness, and that one’s just fun ’cause you just get to, um, light fires and put stuff out then first aid, which I definitely always want a refresher on.
The CPR dummies at this place, they had lights, um, and it lit up green if you were doing it right, and I haven’t used a dummy that was so advanced before, so that was quite good. I realized I wasn’t pressing hard enough. and then yeah, last two days is working at heights training, which is the most intense ’cause you got your harness on all day and, um, you know, climbing up and down and rescuing people.
this was Rite Training in Goulburn, and, um, the [00:03:00] instructor’s name was Claire. highly recommend doing that one.
Allen Hall 2025: Is that a general requirement in Australia that you have GWO before you can climb?
Rosemary1: Like, yeah, they will sometimes, um, let you climb if you are babysat by people. I would not recommend other engineers, like if you’ve never climbed a wind turbine before, like I would really not recommend that you just go up with a team and haven’t done the training because you do need to be able to use a ladder safely and, um, you can, y- you can easily, like even inside the nacelle, you could easily hurt yourself really badly if you’re used to working in an office, uh, you’re upping your danger level by, you know, like many, many, many times by going up a turbine and it’s just something that you gotta take seriously.
Allen Hall 2025: How busy are the courses in Australia? Are a lot of technicians trying to get in and get trained?
Rosemary1: No, it’s people that have a job that are getting trained. But there were heaps of techs in this course. There were maybe eight or so, which is also part of the reason why it took a really long time.
Allen Hall 2025: So [00:04:00] this week, as we record, y- you’re presenting a blade repair course for engineers and technicians. a completely new area that you’re, uh, going into in terms of offering advice and expertise that it’s really hard to find on the planet. It’s probably a, a, a busy or, or requested course, I would imagine, in Australia, where you just don’t have access to a lot of the manufacturers.
Rosemary2: it’s a, it’s a course for just for engineers or technical type people, um, but including hands-on stuff. So the way that I I forced this to come into being was just the last five years. I, um, you know, I started working a lot on wind turbine blade repairs and, um, people would ask me, you know, “Have these repairs been done right?”
And the thing is that the only repairs that I had anything to do with when I was working at LM were weirdo ones, right? [00:05:00] Where the normal, like a technician couldn’t, couldn’t handle it. It was outside of, um, yeah, their, their standard, uh, kind of repairs that they can do for whatever reason. and now in the work that we do at Part Load, it’s primarily normal repairs, and I just didn’t know exactly what technicians know. You know, how do they, how do they know whether they can repair it or not? What do they know before they go up there?
When are they calling the engineer? Um, all that sort of stuff, like the normal stuff. eventually it became less about me learning, ’cause like I said, I kind of picked up most of it. Um, but now I’ve got staff that I’m training up to be, uh, you know, composites engineers and to work with these kinds of issues. There’s a lot of repetitive tasks involved in what we do when we, like, assess the condition of a wind farm.
A lot of what we do is look main- manually looking through photos and thing- if things are classified right or not. I [00:06:00] Found this guy from Direct Wind Services, Jurij Eska. He’s a blade engineer. He’s worked in Europe and then come back to Australia, so a little bit like me. And, um, I just worked with him on a few projects and I’m like, “Oh, okay. Well, this guy, uh, he really gets it.” And I asked him, “How do you, how do you train your technicians?
What course do they do? Maybe I can do that course.” And he said, “Oh, we train them ourselves.” And so then I asked him to put this course together. So where we started off the course yesterday, that was, um, uh, an indoor session where I was talking through how are blades designed, uh, certified, tested, manufactured, um, what kinds of manufacturing defects can you see and what do they do about them in the factory?
‘Cause you know that they’re doing a lot of repairs in the factory already before you ever see a, a brand new blade. and then the next three days we’re going to be working on, um, yeah, grinding and [00:07:00] infusions and a bit of a, a bit of theory about, um, composite repairs.
Allen Hall 2025: What do you feel like are those key skill sets that engineers should know how to do, maybe not as well as a, a professional technician that does it a lot, but at least at a beginner’s level should be able to complete them before they start repairing blades on their own and giving advice about how to repair blades?
What, what are those key items?
Rosemary2: part of it is that I want them to be able to understand what is a bad damage and what’s not a bad damage cause you look a lot at images from the outside, but it’s really about what’s on the inside and how deep it goes is the real thing.
So, um, it’ll be about learning, you know, developing some judgment about, um, how bad it can be and how bad it can look on the outside. We’re not gonna be looking at so many real damages ’cause like obviously we’re just dealing with pieces that are in the, um, in the, uh, workshop and Yuri has [00:08:00] made some samples for us, um, purposely made them badly so that we’ve got some, you know, damage to find.
Allen Hall 2025: Are you addressing carbon fiber at all?
Rosemary2: Uh, I actually haven’t asked about that. I don’t think so. Carbon fiber is, um, is a real pain to work with because it’s conductive. Like, even grinding it makes a bit of a hazardous work environment. We did talk a little bit about the different materials yesterday and, um, about pultrusions. And actually, it turns out Yuri used to work somewhere where they, uh, manufactured pultrusions, and I had always, I was always under the impression that a pultrusion is, you know, like, perfectly s- perfectly straight.
That’s the point. And he’s like, “No way.” No way. There’s waviness in the pultrusions
Allen Hall 2025: And on March 3rd through 5th at WOMA 2027, Rosie, you’re gonna give part of this course as part of WOMA, right?
Rosemary2: Little, little mini course. We’ll have to decide what, what makes sense to include, ’cause it was… Yeah, I went through really a, a fair [00:09:00]bit about blades yesterday, you know, like why they are shaped the way that they are. So we had to talk about aerodynamics and, um, why they’re made of composite. So we had to talk about, you know, like composite materials, like how, how they, how they work So I don’t know if, uh, people wanna write in comments that m- we should, we should do some sort of, um, poll beforehand to see what are the topics that are most interesting to people, ’cause I think we’ll have a half day, right? So we’ll need to be, we’ll need to be focused.
Allen Hall 2025: the description of repairs and what repairs should look like could be tremendously valuable. Everybody who has seen a repair always wonders, “Was that repair done right?” And s- and if you can have some general tools to know, like, “Uh, maybe there’s something not quite right here,” or, “That looks like a solid repair,” that would be a tremendous help to the industry, p- particularly for asset managers
Rosemary2: Yeah. And you know what I think is even more useful than being able to pick out when it’s wrong is to be able to know when it’s right. You can– Y-you know, like it is so– [00:10:00] It’s such a relief. Like it takes such a mental load off you when you’re just like, “Yeah, that’s all, that’s all good. That’s normal. Okay, I know that that– I knew that that would happen, so this is not a surprise.”
‘ know, once you know you can make that judgment, you can do it very quickly and focus your attention where it should be, so you don’t need to stress for an hour over every repair. You’re just like, “Yeah. Good, good, good, good, good.” And then, “Mm, please explain why you have chosen to not, not repair this, but just put a Band-Aid over it.”
that’s the goal of this training is to get everybody, y-you know, technical people, not people who wanna ever be a blade repair technician. They’ve got their own training that covers what they need to know. But this one is just, yeah, getting people like asset managers or my employees to learn what they need to know about composites, given that they have already got a strong engineering education.
So, um, you know, they know a lot of the stuff, but just need to know the composite-specific stuff and wind turbine blade-specific stuff
I will run this course again, by the [00:11:00] way, ’cause there was a lot of people who wanted to do it I couldn’t fit in. So it’ll happen at least once. I’ll keep on running it until everybody that wants to do it has, has done it. But, um, yeah, feel free
to get in touch
Allen Hall 2025: So if you wanna attend Rosie’s short blade course at WOMA 2027, just visit woma2027.com and register today
Allen Hall 2025: [00:12:00] Well, over in Canada, they just approved a, really a wind farm big enough to power a small city, and almost none of the electricity is going to the grid, which is a very interesting aspect to some of the things that are happening in Canada at the minute.
So up in Nova Scotia, uh, they’ve conditionally approved the Ocean Lake Wind Project. This’d be the largest wind farm in the province’s history. Up to 158 turbines will rise, uh, generating as much as 1.2 gigawatts of power. But this power is not headed to households in Canada. Nearly all of it will be feeding Everwind Fuels’ green hydrogen and ammonia plant at Point Tupper, where clean electrons will become a fuel that can be shipped across the ocean to Europe. And Matthew, there’s been a lot of [00:13:00] projects like this in Europe that have stopped more recently, particularly in northern Europe and up in Scandinavia, uh, on the hydrogen side. Or at least they’ve slowed them down. Canada seems to be going into that breach maybe to fill that void. And is there a marketplace for this to occur up in Canada?
Matthew Stead: Yeah, I think it’s very interesting. Um, you know, like you say, a number of canceled projects, and in Australia there’s been numerous canceled projects. So I like, um, the analogy or use of the term hopium rather than hydrogen, um, where, um, everyone’s hoping hydrogen will be the answer. Um, although, you know, what I, what I’ve read and understood is that, um, you know, the commercials just don’t really stack up and, um, yeah. So in terms of South Australia anyway, um, there was some major, um, hydrogen, uh, development planned with, um, you know, it, it never stacked up. So, you know, it sounds like a great [00:14:00] idea, um, but I’m not sure that the commercials will ever stack up unless you’ve got that guaranteed offtake for the, for the ammonium
Allen Hall 2025: Yolanda, what kind of uphill battle is this to get this wind farm up and running knowing that it’s one customer and that commercial market is a little shaky at the minute?
Yolanda Padron: what we saw, they have a lot of ca- caveats, right? So they’ve, they need to secure the customers before they start building and before they do anything, um, behind the meter. But it’s, I mean, it’s, it’s a pretty big wind farm, and it’s pretty far up north. But I mean, we, we talked to someone in, in northern US today who was having icing issues.
So I mean, of course we know Canada is no, no stranger to that, if they do make it work, I think it’d be really, really exciting to, to have sort of one technology power another, um, instead of just what we’ve been hearing a lot of the potential data centers and, and just wind po- [00:15:00] powering data centers.
Matthew Stead: Why not data centers? You know, seriously, like you said, Yolanda. why not go something that does have commercial demand?
Yolanda Padron: we’ve talked a lot about the potential of da- data centers, right? And we’ve talked a lot about people wanting to do them. Um, but there’s also a lot of talk of potentially doing data centers up in space and a lot of talk of maybe what if we do it offshore or, you know. And so I think there’s a lot of what ifs with data centers.
Of course, there’s a lot of what if with this, but just from a technology standpoint, I think this is really intriguing to have something that’s, that’s a little bit even more out there than what we’ve heard so far
Allen Hall 2025: Is it a build it and they will come type of s- situation here that hydrogen and ammonia may be the, the first offtake, but realistically, if that doesn’t work out, they can still connect to the grid and feed Canada, feed the Northeast of the United States or something else
Matthew Stead: Also, um, like Japan has [00:16:00] also expressed strong demand for, um, ammonia, and so, you know, they- they’re on the East Coast, aren’t they? So, you know, shipping it from East Coast to Japan is not gonna be so, so easy. I stick by what I said before. It’s hopium. it’s not a plan
Allen Hall 2025: I just saw an article today talking about Airbus continuing on with a hydrogen aircraft, and I think they were gonna work with a Japanese firm to work on that together. Six months ago I thought that died, but maybe it’s still in the offering. Maybe there’s an offtake for hydrogen. B- besides the, you know, replacement for some of the, uh, more unpleasant gases that are used in steel production and in some other industry things, maybe part of this is airplane fuel.
Which ammonia is one of those offerings also, right? The, there’s been a number of efforts to turn ammonia fuel into essentially jet fuel. They configure the engines to burn ammonia, which is a possibility. It does seem remote though, [00:17:00] honestly. There doesn’t seem to be a huge pull for hydrogen, and there’s not a, a major market for ammonia at at least at the moment.
So I don’t know. It, it’s… When you’re talking about gigawatts of capacity you’re gonna build, you, you hopefully have an offtake
for it
Yolanda Padron: if they designed it for it being not connected to the grid, right, it just is kind of like a behind the meter thing, and then could they later retrofit it into there? Like, how would all that permitting and everything
Allen Hall 2025: I–
well, that’s a great question. I– There are a number of, uh, connections between the United States and Canada at the moment. guess is that when they place this wind farm, they have that alternate route lined up, just like any wind farm in here in the States, that you’ll find them real close to high-voltage transmission lines.
Generally, those are the easy ones because transmission lines cost money and take time for permitting. I’m not sure Canada has those kind of restrictions, right? But Nova Scotia is not the easiest place in the world to do heavy construction work, just the [00:18:00] nature of Nova Scotia. It will be fascinating to see how they progress with this, but it’s something to keep an eye on because a lot of other projects like this have slowed down
Matthew Stead: Do you remember when some of the OEMs were talking about, um, putting electrolyzers on their offshore wind turbines? So the, the theory, the theory was you’ve got offshore wind turbine, you don’t connect it to the grid standalone, um, and you generate hydrogen or, uh, possibly ammonia on the actual wind turbine.
And then every now and then you just decant it, you know, drive up with a boat, you know, plug in the hose, and then suck out the hydrogen or ammonia. So, um, yeah, once again, all of those have gone quiet, haven’t
they?
Allen Hall 2025: speaking of Japan, a global oil giant is walking away from the Japanese offshore wind project, uh, but the project’s not dying. BP has told its Japanese partners it intends to withdraw from a wind farm planned off Yamagata Prefecture, uh, apparently worried about [00:19:00] profitability. The 450-megawatt project sits, uh, just off the coast, and it is led by trading house Marubeni, which says it will press ahead without BP.
Kansai Electric and Tokyo Gas remain on board also. So BP’s exit follows really a, a brutal year for Japan, where Mitsubishi has, and some others, have pulled out of, uh, at least three projects so far, uh, over rising construction costs, and I think a lot of that’s tied to inflation. Uh, the ambition’s still there for, uh, for a number of companies, but it’s just getting harder and harder to do projects in Japan.
Is this just the nature of the economy in Japan at the moment, or is this more about Japanese policy on the offtake,
Matthew Stead: I, I’m not really deep into the details but, you know, it just appears to me like a blip. I mean, there, I think there’s a lot of commitment in Japan to, you know, carry [00:20:00] out their offshore developments and I, I think this is probably more just a blip, um, and a little, you know, internal corporate, you know, argument rather than a sustained issue on offtake agreements and so forth
Allen Hall 2025: Well, Yolanda, how hard is it to keep partners on a wind development in general? Are there a lot of moving pieces there until the turbines hit the water or hit the
earth?
there’s
Yolanda Padron: I think a lot of moving pieces, but not, uh, I haven’t seen a lot of changes once it’s been publicly announced and everything’s, you know, everything’s been signed and everything. Um, I do think this is really interesting. I know we’ve talked a lot about, about having, about the idea of like sometimes people think wind’s really expensive, and the way that we’re gonna make wind work is just making it cheaper for everybody and just optimizing it as much as possible, um, and, and just being, having the turbines be as resilient as possible, right?
And I think such a strong player just backing out maybe [00:21:00] will incentivize some of the people in Japan to sort of try to see how they can optimize it a little bit more. I’m really excited to see it. I don’t know. It’d be… I think it’d be a nice it
Allen Hall 2025: Isn’t the bonus to offshore wind the price stability? Although the price may be higher today than you may be happy to pay, the stability of that price is a huge leverage point when you compare it to things like oil and gas or natural gas, um, in particular, which are highly volatile, that for electricity, at least you have this fairly steady source at a fixed price that you can plan out 10 years, 20 years, 25 years, maybe even 30 years. And as batteries become more prevalent on the grid, that the math even gets better over the years. Isn’t that the bonus? And, and if [00:22:00] everybody can focus on the long-term effects to the economy is where all the action will be?
Matthew Stead: Yeah, I mean, when I first, um, started looking into wind, you know, 10 plus years ago, I, I won- wondered why. Why would you build offshore with all that expense? And then, you know, it became clear to me just around the, um, you know, the diversity, you know, the, the fact that you might get more wind at times that you don’t get onshore wind, and the fact that it’s more consistent.
Um, yeah, and, you know, so those… I- it’s really a trade-off, isn’t it? Between the capital costs and the, um, more reliable, more consistent, um, offshore wind. So I think, you know, I, I was convinced at the start, I thought it was crazy, but then obviously it’s, it’s a, it’s a… it makes sense
Yolanda Padron: Yeah, I agree. And I think, uh, depending on where you’re having your offshore wind farm, you run into things that you maybe haven’t run into before, right? I know onshore we run into a lot of things in the [00:23:00]US and Australia that we, you know, the, the turbines just maybe weren’t designed for, or there wasn’t a lot of research being done because it was being done in Europe and, and the conditions are really different.
Um, and just the same way, you know, the sea is different in different places. There’s different depths. There are diff- different things that you need to worry about. but yeah, I, I completely agree that there’s a lot more generation, um, offshore. It’s, it’s bigger turbines. Um, there can be bigger, larger costs. You know, if you need to do a blade replacement or something, it, it can get, again, really expensive really quickly. But, but it’s, it’s a trade-off for sure.
Allen Hall 2025: We’re gonna take a quick break, but when we come back, we wanna talk about a place where wind is being fought over versus projects slowing down
[00:24:00] over in the UK, there’s a big fight about offshore wind, and not just about where wind turbines will be planted, but more about how they will affect other wind turbines.
So RWE is defending the UK government’s approval of its three-gigawatt Dogger Bank South project, which won its consent order, uh, basically a month and a half ago. Uh, but the developers next door are taking that approval to court. Equinor, SSE, Vårgrön own the neighboring 3.6-gigawatt Dogger Bank wind farm, and they have filed for j-judicial review.
Their argument is technical, but the price tag is not. They say wake effects, where one wind farm steals the wind from another due to turbulence, could cut their output and cost them between €500 million and [00:25:00] €669 million over the life of their project. That’s a lot of money, Matthew. A half a million euros is not something to ignore.
It looks like this is headed to some judicial court or maybe arbitration. Wake effects, which are actually not that well understood from what I can tell at the moment, there’s a lot of discussion and argument about, uh, how real are they or, or what effect they can have on power output. Uh, there’s a lot of money at stake, and the location of some of these wind farms is pretty close to one
another
Matthew Stead: you know, we always, always talk about, you know, AEP loss and, you know, the, the challenge is actually measuring it. And, um, you know, I’ve heard different numbers, but, you know, plus or minus half a percent of AEP loss, um, appears to me from what– in discussions, you know, the, the limit of what you can actually ever measure on a good day.
Um, I just wonder, I mean, while those numbers, you know, €500, um, [00:26:00] million is a, is a big number, um, but what is that as a percentage of the overall output of that, of that facility? Um, I, I don’t know the answer, but, you know, if, if it’s, you know, half a percent, I think you’d be struggling to, um, struggling to justify that, that wake effect loss.
I mean, you know, going back to what you said, Allen, you know, there are wake effects of some sort, but it’s a question of how much. I mean, that-that’s why aircraft don’t take off, um, too closely, isn’t it? Because there’s wake effects. Um, so it’s definitely a given, definitely a given. Um, but, you know, how much of an impact it truly is.
Um, and I mean, there’s always other variables, you know, variables in the weather, you know, wind patterns, da, da, da, da, da, da, da, and how much do this– does this actually compare to those other, other variables?
Allen Hall 2025: Yolanda, how would you even mitigate wake turbulence on an adjacent wind farm? Are there ways to do that today?
Yolanda Padron: I think the, the aerodynamics, Allen, would [00:27:00] be a lot more in your court than, than in mine.
Matthew does have a really good point. I mean, what are we… With the UK wanting to ramp up offshore as much as they want to ramp up, right? They’re not going to just cancel a large project, and they need to… I mean, it’s not, uh, there’s a finite amount of space, right? So what, I mean, what, what are you, what are you gonna do?
It’s like, it’s what, like, what happens in onshore where you, you really hope maybe that you don’t get a wind farm that’s really, really close by. Um, but you might also want to plan for it. I mean, I know of sites that have le- that lease a little bit of extra land so that way no one else can lease it, or that they can, they can use that to, to travel between turbines.
Um, and it’s, I mean, it’s, it’s kind of… Isn’t it kind of just part of it, part of the trade?
Allen Hall 2025: it has to be, right, at some point. [00:28:00] The question in my mind about all this is how much wake is there? Is it directly impacting the adjacent wind farm? Is there– are there things that can be done to minimize that wake turbulence? I think the answer is yes, but as wind turbine blade designers, I haven’t seen the same level of wake reduction that we have seen more recently in aerospace.
It’s complicated to do some of these things on a wind turbine blade. You’re mass-producing. You’re making a blade a day or a blade in a day-and-a-half timeframe. Are you gonna design this really aerodynamic tip to go on to reduce the wake on a particular wind farm? Probably not, right? So it’s, it’s– is it worth doing that versus the, the cost it would be?
So it’s gonna cost 500 million euros in loss to an adjacent wind farm. Do you put that 500 million into the design effort and the molds and [00:29:00]everything else to make these blades different? Uh, it’s a tight trade-off, right? It– from the engineering side. It may be better settled in the courts, honestly. Just it may be cheaper to do it that way.
Matthew Stead: Uh, I, I was gonna go down a different avenue. I mean, obviously there’s always curtailment. There’s always curtailment due to grid congestion, et cetera, et cetera, et cetera, maintenance. I mean, if they, if they just– when wind is coming from a certain direction, they could just de-rate and, uh, just not absorb as much energy, um, out of the wind when the wind is coming from that sector.
And so that would be a way of, um, not modifying the turbine, just de-rating it under a certain wind condition. I mean, the same thing occurs with noise curtailment all the time. Um, so there’s, there’s noise modes. There could be a, a wake loss mode. We should trademark that
Allen Hall 2025: Well, you know who’s gonna make money out of this no matter what? The
lawyers.
Allen Hall 2025: [00:30:00] Well, in this quarter’s PES Wind magazine, there are a number of great articles, and you can download the entire magazine and all those great articles at peswind.com. There’s a nice little article from Enerpac Tool Group, and if you’re not familiar with them, they make a, a number of tools that are handy in the wind industry.
Uh, and, you know, routine torque checks is kind of a pain, right? And the problem with a lot of those checks is that you have to haul around a heavy hydraulic pump to do it. And so if you’ve ever been to a trade show and seen some of these [00:31:00] pumps, it is a pain. And if you h- have to move around, especially on a w- wind site a lot, you really don’t wanna have a heavy pump that maybe is made for something, uh, more robust.
Uh, and you need something that’s portable. That’s what you really need, right? So the Enerpac Tool Group has really created this, uh, LU series they call. Which is a lightweight, portable, hydraulic pump, which is for intermittent work, which is what happens on most wind sites. It’s intermittent. Uh, so the product line director, Angie Wallace, uh, talks about this and says technician feedback has shaped this new tool, uh, from multiple carrying handles and an upward-facing gauge.
And that is a big thumbs up from me. When you put the gauge on the side of the tool where you can’t see it, such a problem. It’s like they’ve never used it. Well, obviously, the Enerpac has been talking to technicians, and they put the gauge where the technician can actually see it. Uh, and it’s designed to go through towers and, and tight [00:32:00] spaces.
Uh, so this is made specifically for offshore conditions. It’s ruggedized, and it’s a great tool. And a lot of times, Matthew, when you s- see the technicians about and some of the tools they carry, you’re like, man, that is not a good tool for this. That is, that is too much to be hauling around, particularly uptower.
It’s nice that we can see some tools that are designed job
Matthew Stead: I, I’m completely convinced. I, I don’t have much to say. Um, I mean, my, my day job is, um, you know, designing products and working out what products we’re going to, to work on, and, you know, the customer is the main voice you should listen to, um, at least in the first step. So always listen to the customer first, and I think from what you’ve described, customer first, and then develop the product to suit the application.
Yeah, so yeah, I’m convinced
Allen Hall 2025: Yolanda, you’ve seen Interpack on sites, haven’t you? It does seem like I run across them once in a while at some of the US
sites
Yolanda Padron: Every once [00:33:00] in a while. I do gotta say I love the idea of when, like, actual, like, boots on the ground people’s feedback is taken into consideration for, for anything really. And so this is, this just makes me really happy because I think a lot of times, like, as engineers, like, we love the idea of just, oh, I’m gonna do this really cool fancy thing, and then it’s just it- no one can use it, or a very specialized person has to be able to use it.
And so actually doing, you know, modifying a product so that it, it makes sense for the people using it, and I know we’ve, we’ve all talked about it a lot internally and, and we continue to work towards making it easier and easier on, on the people actually installing the product. Like, this is, this is really exciting.
Allen Hall 2025: So if you need a lightweight pump for tightening some bolts uptower, particularly if you’re offshore, take a look at this Enerpac line of LU lightweight series tools. It’s well worth it. And at that same time, you should check out PES Wind magazine. Just go to [00:34:00] peswind.com
That wraps up another episode of the Uptime Wind Energy podcast. If today’s discussion sparked any questions or ideas, we’d love to hear from you. Reach out directly to Rosemary, and don’t forget to subscribe so you never miss an episode. for yolonda, Matthew, and Rosemary, I’m Allen Hall, and we’ll see you here next week on the Uptime Wind Energy podcast.
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