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PEAK Wind Masters Site and Turbine Selection

Lene Hellstern, Director of Engineering at PEAK Wind, discusses the complexities of onshore wind siting, the advantages of using LIDAR technology, and strategic considerations for turbine selection.

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Allen Hall: We’re back with Lene Hellstern, the Director of Engineering at PEAK Wind, and we’re talking about onshore wind siting, which is a really critical issue that a lot of operators have difficulties with. And I’ve seen it in the United States and it’s not good.

And I’m wondering from your perspective, what are some of the problems, Lene? Well first, welcome back to the podcast.

Lene Hellstern: Thank you. And thanks for having me repeat experience last time, so I hope so. I thought I’ll pop in again. 

Allen Hall: Well, it’s good to have you back and thanks

Lene Hellstern: for coming to Copenhagen.

Allen Hall: Yeah, well we love Copenhagen.

It’s great. Uh, I just wish it was a little bit warmer. Yeah, the sun is terrific. Yeah. When you’re in it, well, at

Lene Hellstern: least I fixed that. Right. Yes. It’s not raining. It’s not raining. Yes.

Allen Hall: We, we quite enjoyed it. Uh, but I’m trying to get an understanding of what the underlying issues are with onshore wind siding and why some of the operators have difficulty later on.

Let’s just start with the sighting [00:01:00] itself. Yeah. Is usually, we’ll see a wind mast out on site for several months, maybe a year, maybe two years. To try to get some wind data. We would

Lene Hellstern: really like that. Yeah. Okay. But, uh, the preferable measurements are lidars.

Allen Hall: Oh, lidars. Yeah. I have not seen a lot of lidars in use.

Lene Hellstern: No. You, you need to get some more.

Allen Hall: Why?

Lene Hellstern: Um, because they reach higher.

Allen Hall: Okay.

Lene Hellstern: Um, and you can, uh, you can, you can move them around. Right. And the hassle of installing a Met Mass that’s a hundred meters tall, is, uh, is it a problem? Quite, uh. Quite it, it cost a lot more. Yes. Um, and, and the lidars, they, they just, they’re better and they measure higher.

And you can, you can have one sort of mother lidar and then you can move the other around and you can cover your wind resources and site suitability much better on the site. So I would definitely recommend

Allen Hall: lidars. Okay. How the lidars use a [00:02:00] good bit of power to make them run, correct? Yes. So you need a decent power source?

Yes.

Lene Hellstern: You do? Yes.

Allen Hall: Okay. Yeah. I, is that one of the difficulties why they don’t use a lidar? Is it just in a lot of remote areas, they don’t have the power source to run it?

Lene Hellstern: It could be, or it could be the, the lack of knowledge. Right. Traditionally we have used med masks, yes.

Allen Hall: Forever.

Lene Hellstern: Uh, so, so it could be, and then there are also some, um, uh, some issues with uncertainties because the lidar is the, the standards are not up to date.

I would say that’s the political way correct way of saying it. So. Eh, the standard actually introduces more uncertainty on the lidar that’s really not necessary to, due to a calibration with a me mast. Um, so that there’s some, there’s some things that needs to improve in that area

Allen Hall: because a lidar should be a lot more accurate than a met mast.

Lene Hellstern: Yes. Yeah. Yeah. But, but the, the downside of the lidar, so that, that is not often we see that, is if you don’t have enough particles in the air, you have [00:03:00] an issue because then you are, you’re simply not gonna be able to measure. The, the, uh, velocity of the particles because they’re not there. And then you have a low availability on your measurements.

But, you know, most places there’s, there’s a quite a lot of dust. There’s pollution. Um, so there, there are things in the air that we don’t see, but the lighter sea and then you can make the measurements.

Allen Hall: And as the hub heights have gotten taller, it gets a lot more difficult to get a met mass up that high.

So the lidars go can measure winds. How high up in the air? How many meters? I

Lene Hellstern: think at least 250 meters. Wow. And, and you want, you want to, you know, traditionally you would only measure at hop height, but you wanna measure at the, the, the rotor surface, right? So you wanna measure at tip height, and you wanna measure at lower top tip and lower tip to, to see what, for instance, what’s the wind share across your, uh, rotor disc.

Um, which

Allen Hall: you cannot really do with a met mast at all. You can’t do that. You have no [00:04:00] wind share knowledge. From that instrument? Sort of, yeah,

Lene Hellstern: you can, because you can make, you always, you, you have a met mass that’s at least at hop height, and then you have, uh, anemometers and wind veins and I don’t know what on all the way down.

Um, and you can with, without that equipment, you can, you can measure on the lower part of the rotor, but not the upper part. So, so you, you do get some possibilities to measure wind share, but not as good as, um, for instance, a lidar. Yeah.

Allen Hall: So how many lidars would you typically need on a 100 turbine site?

Lene Hellstern: Well, that depends.

Allen Hall: Okay.

Lene Hellstern: Because you have a, if you have complex terrain,

Allen Hall: right?

Lene Hellstern: Yeah. You may want a lot. Right. That’s what I

Allen Hall: was wondering if the more hills and valleys, the, the more lidars you will need, or more samples you’ll need, or maybe the longer duration you’ll need. Yes.

Lene Hellstern: Yeah. And you, you would wanna, you know, it’s always the best to measure it.

I think it’s [00:05:00] ideally five years. Nobody does that five years. Nobody. No, no. But you should at least have two, right?

Allen Hall: Yes.

Lene Hellstern: Uh, and then you should do a proper long term correlation. Um, so, so that’s, and how does

Allen Hall: that, how does that accomplish Right now, let’s just say we have a met mass. What I typically see is, has been a met mast out in the middle of the United States where the winds are pretty good.

Speaker 3: Yeah.

Allen Hall: And they have data. They have some data. Yeah. So typically I’ve seen them out there a year, maybe two years, and then. The, but the sites are massive. Yeah. They’re, they’re square miles. Yeah. Dozens of square miles. So it’s big.

Speaker 3: Yeah. I

Allen Hall: dunno whether it’s in kilometers, but a lot of square kilometers. So then they are trying to interpret interpretate that data that they have from the Met Mass on top of that.

I think they’re looking a little bit forward in terms of who, what other wind farms may be surrounding us in the next several years. Yeah.

Lene Hellstern: And that’s, that’s one of the challenges we have because there’s a lot that. Uh, you, there’s a lot of guessing.

Allen Hall: Yes.

Lene Hellstern: Um, and so if [00:06:00] you are planning a wind farm, you wanna know what goes on in the area.

You wanna map out the already existing turbines, uh, and what, what hop height, what rotor size, because you wanna be able to model them in your calculations.

Allen Hall: That was really good. Get to my question about how difficult this process is and how you try to address it. In the United States, we turn over wind turbines every 10 years, so there’s a repowering happening and.

Almost always, the rotor size gets substantially bigger. 20 to 30 to 50% bigger. Right. So there’s fewer turbines, same location. Yeah. And the turbines are roughly in the same spots, but they’re just bigger rotor diameters. How do you then prepare for that? Do you use the old data or is the old data even applicable?

If I’m really dramatically increasing the rotor size, do I need to be doing more? LIDAR measurements before I make that repower, or how do I even cite that? Right.

Lene Hellstern: Uh, you can, if you have some good SCADA data from your turbines, you can do some [00:07:00] modeling. And many of the sites actually have a met mast. They do a lot Yeah.

As a reference, right? Yes. Right. But that will be on it, it will have sectors where there’s a lot of weight from the existing.

Allen Hall: Okay.

Lene Hellstern: So, and so I would, I would, I would try, I would filter your SCADA data from your site and see if, can I, can I use this? I’ll take a look at the mid mass state and see, can I use this?

If not, I’ll start a me mass campaign. Now the problem is if you’re reusing the spots now, well first of all, that’s a little bit difficult reusing because your foundation is dimension to an old generation turbine. Uh, let’s say take someone a hundred, a hundred, uh, meter rotor, right? Right. But now you’re going up in size.

Um, so that means everything gets heavier and bigger, right? So your foundation may not be suitable. The old foundation, normally they’re over dimension. So you can, you can extend life or you could repower on them, but you would want a bigger turbine. [00:08:00] So you don’t necessarily want to use the opposition, right?

And then you would wanna know what is in the pipe. You know, when can I get my, when can I start digging? Right? When can I start installing? Uh, what is in the pipeline at that point from the OEMs? Because sometimes it actually takes five years from, you start planning until you, you, you start digging. And in that time, if you, you, if you space with today’s models, you are gonna have two shorter distance between the turbines because the new turbines on the market that you would wanna buy has increased significantly.

Um,

Allen Hall: and that’s a real problem. Yeah. Like that, this, this. Between the, the siting time, the met mass, the LIDAR data, getting enough data and having to make the decision about a turbine relatively early because the production lines are not operating at full capacity right now. Yeah. It’s hard to get a turbine.

So you are 3, 4, 5 years out. Yeah. How do you plan for that on an onshore site?

Lene Hellstern: Well, [00:09:00] you, you gotta guess a rotor and guess a, a turbine site. Okay. Right, right. So, but

Allen Hall: do, do the engineering staffs that a lot of operators have that inside knowledge because it seems like smaller operators, I’m, I’m not the urals of the world, have power and they can see inside the factories and they have a really good connection and they develop that connection over a long, many, many years.

Speaker 3: Yeah.

Allen Hall: Where newer operators usually do not have that sort of insight. So where do they go to get help?

Lene Hellstern: Well, well, they could go to, right? We could help them a little bit, but. You can also look, if you look at the evolution of the turbines, you can, and I, I’m, I’m hoping we are at a little bit of a pause here in the, in, in the growing size.

So we, we can refine the turbine, we can refine our manufacturing facilities. We, we get better at service and installation. But you can pretty much, you know, guess the rotor. Uh, I’ve, I’ve done that a lot in, in this job and my previous job, because you [00:10:00] look at, if you look at when the. When did what? Come on the market and from what, OEM.

Right. And then you, you know, there’s, there’s other topics you need to look into for, for instance, site suitability. Right? Right. What are, what are the conditions on the site? Um, are you a, we, we categorize in different classes. I, e, c, 1, 2, 3, um, or turbulence classes. A, B, C. And then there’s the, the class I like the least that is the Class S.

Which is special. And then you never know what it is before you start digging in all the paper. Um, but, but you, that’s sort of the first things you need to find out. What class are you? And then there’s a small in that because, um, you may think you are a, a class two or have a class two side, but then it turns out that your air density is unbelievably low.

So sometimes you can actually squeeze in a class three. Turbine on a class two [00:11:00] side and get that much more production.

Allen Hall: Do a lot of operators know that?

Lene Hellstern: No.

Allen Hall: I wondered. Okay. Yeah. Well

Lene Hellstern: maybe the, it’s not so much the operators. It’s the developers. Developers. Sure. Yeah, yeah, yeah. That has to, to, to dig a little bit more into the lovely engineering science around turbines and.

And, and then do more site suitability because you can actually improve your, the value of your project quite significantly.

Allen Hall: That’s what I wonder if, if you spend a good extra amount of time maybe spending a little more money to get LIDAR measurements Yeah. And to do them for a slightly longer period of time, does that have a return on investment?

Lene Hellstern: You get, you get less uncertainty. Right. And then I think some of the issues or some of the mistakes that the developers do, they. They do a wind, they do a, a production estimate, but that is not the same as a site suitability or uh, [00:12:00] you know, also, some people also think if I do a wind resource assessment, then I’m covered.

No, because that is the input to the site suitability. Now you also need to do the site suitability. So you know, I would start out doing a wind resource assessment, right? Then I would do a site suitability and then you do your production calculator.

Allen Hall: And how long does that process take, generally?

Lene Hellstern: Oh, that’s always a cue.

So it could take, uh, it depends on who you use for this, right? But it could take four to to eight weeks.

Allen Hall: Okay. That’s not horrible. No,

Lene Hellstern: no, no.

Allen Hall: Alright, so it, it is relatively efficient compared to other things that happen in wind.

Lene Hellstern: Yeah. If you are have a complex site, it can take longer because you need to run a lot more calculations due to, uh, the comp complexity of the terrain, right?

Mm-hmm. You can have issues with inflow, angles, uh, ware, wind share, uh, [00:13:00] all the lovely technical things. Yeah.

Allen Hall: Well, and because we’ve developed so many sites to date, all the best wind sites have turbines in them mostly right now, and. We’re, we’re starting to get along the fringes of that good wind area.

Yeah. And in some cases, does that change the way you do the analysis and do the approach?

Lene Hellstern: Yes, but, um, some of us have done that for a long time because it’s not good enough to have good wind if you don’t have good grid. Um, so, so for me, a good wind side, you know, we, I, I spoke with someone yesterday about.

The best, uh, uh, wind resource in Sweden. Um, but, but if that area doesn’t have a good grid, then you know it, I can’t harvest the wind. Right. Right. Um, and it’s the same in, in the US right? You, you have some grid issues. Um, so we have a lot of

Allen Hall: grid issues. Yeah.

Lene Hellstern: And if you don’t, everything is [00:14:00] combined.

Everything works closely together, right. Uh, the technical, the commercial and the finance. So if, if, if that is not. Well, um, covered in a, in a, or, uh, investigated in a project, you don’t have a good project. Um, is

Allen Hall: the grid the limiting factor in a lot of onsite onshore sites?

Lene Hellstern: I think the world is becoming more and more electrical, which it is, which I think it’s good.

Mm-hmm. And I don’t think that they, we can point at any government that was super duper on, um, expanding the grid. Um, no. I know there are issues in Texas. There are also issues in Denmark where I’m from. There are, yes, there’s issues in Europe. So, um, we, we need, we need massive in investments from the government to build out this grid.

It’s, it’s not, um, enough to say we want clean energy and then do nothing. Right. Well

Allen Hall: this is where, where, where the ons onsite versus the onshore versus the offshore comes in. Yeah. [00:15:00] Is the grid.

Speaker 3: Yeah.

Allen Hall: So in the US and other places, uh, there’s been. A, a lot of concern about offshore wind, but offshore wind, you can get to a grid relatively easily.

Yes, usually. Yeah. Yeah. And it’s less bureaucracy to lay cable in the ocean than it is to run transmission lines over land.

Speaker 3: Yeah.

Allen Hall: So is this starting to flip a little bit because of the onshore limitations in the grid that we’re seeing more offshore, just because it’s easier.

Lene Hellstern: Well in Europe, but I would not say that in the us Right.

But, uh, but, um, um, it, it, it is easier, but it’s also much more complex to put up these, uh, offshore projects. They are in development for many, many years compared to onshore.

Allen Hall: Right.

Lene Hellstern: So, so onshore is a little bit of a, depending on country you are in, if it’s overpopulated right? It’s, it’s difficult, but it’s, it’s a much more of a quick fix, uh, [00:16:00] onshore.

For, uh, lack of energy. Right, right. But, but it just requires it, yes, it requires the grid and yes, it requires that you don’t do it in a popula populated area. We don’t want to do that. Right, right. We want, we want the open fields, um, where we’re not disturbing anyone. True. Yeah.

Allen Hall: True. But we also want infinite electricity.

Absolutely. So you have to weigh those two off.

Lene Hellstern: I, but I think the turbines are beautiful. So I would, I would love to be able to see one from my house, but I can’t. Yeah.

Allen Hall: We have actually quite a few we can see from our, from our house. Yeah. Yeah. And no one complains. No. They complained for the first few weeks after they were installed and after that it’s been completely quiet.

Yeah. But,

Lene Hellstern: but I do understand if you place turbines too close to a house Right. Sure. That, how that can be disturbing. Sure. Um, I, I totally understand that. Yeah.

Allen Hall: Can we talk about AI data centers and independent grids and how that’s factoring [00:17:00] into some of the decisions about where to place wind sites?

Because it does seem like in a lot of places in the world, these AI data centers are going to go in. Yeah. And they’re making decisions about using natural gas to power the turbines or using wind and solar and a little bit of battery to, to run these centers. Yeah, but that doesn’t necessarily. Wire a connection to the grid.

Does that make it easier in a sense that you don’t necessarily have to have a grid connection, you could put something out in a remote area that it still had good wind and still has good solar with a little bit of battery? And are you starting to hear more action that way, or interest in that?

Lene Hellstern: I’ve, I’ve seen that there’s been, uh, quite some centers that has, uh, made, uh, PPA agreements with, with wind turbine owners.

But they are normally not super close, uh, uh, located to the wind farm. Okay? And I would also say that I would find it a little bit difficult, [00:18:00] uh, if they were remote, because you need a, you need a constant power source and, and the wind doesn’t blow all the time, right? No. So you need, you need a lot of, uh, combination mechanisms, right?

You do to make sure everything runs stable.

Allen Hall: But you may not have neighbors in that case because you could select a site that’s a little bit further away from. Society in a sense. Yeah. Where the, the wind siding may be a little more complicated though because we, we probably haven’t looked in those areas because it’s not connected to the grid.

So you may not have historical wind data doesn’t make the problem just bigger. So I do think in the United States you see like Amazon and Meta and Google talking about using wind and solar to power some of these data centers. Yeah.

Lene Hellstern: And, and they are, and I know that there are, uh, agreements that has been signed.

But I, I am, I don’t think they are close, uh, you know, in close proximity necessarily.

Allen Hall: Okay.

Lene Hellstern: But of course the, the, the electricity needs to be to be transported in the grid. Right. [00:19:00] And it’s not like it’s a microgrid around the data center.

Allen Hall: I think you may see more microgrids.

Lene Hellstern: Okay. Well that could be interesting.

Well, that’s what

Allen Hall: I’m wondering because there may be more microgrids that won’t even be microgrids because the amount of power that they’re gonna use, they’re gonna be decent sized grids.

Speaker 3: Yeah.

Allen Hall: That. Th that becomes even a more difficult engineering challenge.

Lene Hellstern: Well, I think it’s gonna be too expensive.

Allen Hall: You think so?

Yeah. Compared to natural gas or just because No, just,

Lene Hellstern: uh, buying, doing a PPA with a wind farm that may be a hundred kilometers away. Yeah. Right.

Allen Hall: Okay. Um, well that’s interesting. Yeah.

Lene Hellstern: I think the whole, um, uh, burying the cables in the, you know, the whole installation, uh, is, is simply, it’s simply to, uh, it’s complicated cap.

Is too high.

Allen Hall: Okay.

Lene Hellstern: It’s, it’s much more affordable just to buy a PPA.

Allen Hall: Yeah. It may be. Yeah.

Lene Hellstern: Yeah.

Allen Hall: Okay. Well this is, this is fascinating. Can I pick your brain or bother you just a little bit longer?

Lene Hellstern: Yeah, [00:20:00] yeah, sure. Okay.

Allen Hall: So

Lene Hellstern: it depends on the time. Yeah.

Allen Hall: We got 20 minutes. Good. Can I steal 10?

Lene Hellstern: Yes, sure.

Allen Hall: Okay.

Lene Hellstern: This is not my core area, just so you know.

Allen Hall: No, no, no. I wanna, I wanna get, I wanna get back into Yeah. The, the meat here, which is turbine selection.

Speaker 3: Yeah.

Allen Hall: I have my LIDAR data. Mm-hmm. I have my MET Tower data. I have say I have two years. I am really the best wind resource knowledge operator developer that you’re gonna meet.

Speaker 3: Yeah.

Allen Hall: Great. Super. What do I do next in terms of picking a turbine?

How do I even do that? And how does that process look like if I’m talking to OEMs about something that’s still three years from being developed?

Lene Hellstern: Well, you need to start, you, you need to have your planning, uh, your permits in order.

Allen Hall: Sure.

Lene Hellstern: So depending on what country you are in some operate, what you need to apply for the [00:21:00] specific location of the turbines more, it’s more a box.

Uh, so it’s, you say, I am, I wanna apply for 300 megawatt, 500. Uh, please. In, in this area. Um, so then you start looking at your site, suitability, uh, what, what boundaries am I working within? What is my average wind speed in different, these different heights? Uh, what’s more, how do I get levelized cost of energy as low as possible?

Because some people still sit and look at the net capacity factor, but those days are over, right? They are,

Allen Hall: yes.

Lene Hellstern: Yeah. So when, when all alarms should go up, if they say. Good lift capacity factor. Yeah. Super. What’s your live life cost of energy there? Um, so, so then you, now you start, you have a good idea on what kind of a turbine class should I look at?

Then you start looking at who is, do you wanna do self service? Do you wanna have a full service agreement?

Allen Hall: Exactly. That’s what Im really wondering how that works then, because if I [00:22:00] know the basics of the wind site, do I just. Put a proposal together and slide it to Vestus and slide it to ge, or is there still more I need to do before I start talking to them?

Lene Hellstern: You need, you need to ask you yourself and your organization. Okay. Or PEAK. Yeah, but, but we would ask you as well, what is your o and m strategy, right? Do you wanna do self perform? Do you want a full service agreement? What, what’s, how risky do you wanna make it? Is that

Allen Hall: a deciding factor in determining what turbine you want to purchase?

Yeah.

Lene Hellstern: Because then you may not need D-O-E-D-O-E-M to have a service organization close to your site. Right? Let’s say, okay, so

Allen Hall: let’s say you choose vestus because they have a, they want to sell you a full service agreement, generally sPEAKing. Yeah. Where a, a GE typically doesn’t care or not so involved in that.

Lene Hellstern: Okay. But then, but you wanna know, do they have a service organization close to right. Right, right. Or are they gonna re uh, are they, do they need to build it? Right? Is this a new [00:23:00] platform? Do they not have any experience with this platform, the people in this area? Because then you, you know, that’s always, so it’s teething issues, right?

Allen Hall: Sure.

Lene Hellstern: Yeah. So,

Allen Hall: so how does that play into your decision making then?

Lene Hellstern: Well, you know, if you have a, if you have, let’s say, four volumes in this area,

Speaker 3: right?

Lene Hellstern: Yeah. And then you had, you, you look at what, what do they, what turbines do they offer? What service agreements can you get? What availability, you know, how does the contracts, you wanna benchmark the TSAs and the SMAs?

Yes. Um, and to see what kind of, who’s the best player here? There’s a lot of pieces to the puzzle. Well,

Allen Hall: that, that’s exactly what I wanted to get to was, I’m trying to understand how deep you’re going in this. So you’re actually looking to see if they have a service site nearby? Yes. And what the service people have been exposed to in terms of turbine type.

Yeah. And also you’re going a little bit deeper to see how successful they have been. Maybe you, you’ve called the sites

Lene Hellstern: around if I have that information. Yes. Yeah. [00:24:00] Okay.

Allen Hall: Yeah. So you’re making a lot of decisions not based upon necessarily what the OEM is offering as a product, but you’re also looking at what does the next 10, 20, maybe even 30 years looks like.

Lene Hellstern: Yeah. And then you wanna know what, you know, what, what turbines, what pipeline is there, and then you wanna do the tender. Right,

Allen Hall: right.

Lene Hellstern: Let’s say now you’re down to three because the fourth one, that, that was a no-go. Right? So now you have, that’s why I always, I say four turbines per site. You need to pick, pick four different OEMs.

Now you’re down to three. Right? And then you, you, you, you, you issue a tender and you, you get the proposals in. Okay? And then you, you start negotiating and you do your tech, your technical due diligence, right? To sort of dig a little bit deeper and understand the OEMs right. Also give them a chance to say.

Hey, this was an issue before, but we fixed this problem and you can see it documented. Oh, you go, yeah, but you’re still, you’re not there. So I need to account for that. So then you have a dialogue with them, and then, [00:25:00]then you have, you, you then the third one is too high and now you have or can’t deliver, or you know,

Allen Hall: doesn’t have a production schedule that meets your deeds.

Lene Hellstern: Yeah. Yes, exactly. And now you’re down to two, and then may the best one win. Right.

Allen Hall: Okay. So you’re talking about. Several months of gyration. Yes. Meeting with the OEMs or OEMs coming to you even to give their pitch. Meanwhile, you’re evaluating their technical expertise about their turbine, and you’re questioning how the previous generation of those turbines have performed looking forward to say, have you fixed the the existing problems?

And what does the next generation look like? Yeah.

Lene Hellstern: Oh, well, what did they look into? Developing a new

Allen Hall: platform.

Lene Hellstern: Okay. Right.

Allen Hall: So are you thinking about risk in terms of new technology? I’ll, I’ll throw the easy one at you two piece blades.

Lene Hellstern: No, thank you.

Allen Hall: Okay. That’s a, that’s a good response. Yeah. Because I think a lot of, there was just a lot of unknowns about that.

Speaker 3: Yeah.

Allen Hall: Yeah. And then now that we have some service history, yeah. We may wanna rethink that. Yeah. Are there other types of [00:26:00] technologies that would lend themselves to requiring further review?

Lene Hellstern: Yeah, but there’s, I, what I’m hoping is that, that maybe we can pause a little bit on the sizing thing in the. Right.

And then refine the components a little bit more and then, and be more innovative, um, instead in the components. In the components, yeah. And, and improve the manufacturing quality installation service. Right? Because, um, sometimes what I see in the industry is not, it’s an old component, but actually it’s the people that’s the issue, right?

Mm-hmm. We don’t, we are not, we are not trained, you know, we don’t have the technicians trained really in a. We don’t have the people in the manufacturing trained well enough, and so, so we make mistakes. So, and

Allen Hall: are you looking for OEMs that are doing more reflective activity at the moment that they’re basically causing new designs?

And then we always do that, that when we

Lene Hellstern: always look at, when we do technical diligence, how is the training [00:27:00] in the, in the manufacturing, you know, what kind of programs do the different people need to go through? How do you get to a seniority? How do they train them? How do they test them? How many years does it take, right?

Because you can’t do things in five minutes.

Allen Hall: Right?

Lene Hellstern: What’s the turnover at a manufacturing plant?

Allen Hall: See? But this is why you would choose PEAK wind to help you do that process. Because I don’t think a lot of developers, and especially in the United States where we see a lot of it, I see a lot of it developers are about putting turbines in the ground.

Yeah. And then selling that farm to the next owner, right? Yeah. So those long-term agreements don’t really play into a lot of this, and from what I’ve seen, but I think in Europe it’s a lot different.

Lene Hellstern: Yeah. No, but we also have, you know, there are different concepts. There is a built to sell.

Allen Hall: Yes. Right? Yeah.

Lene Hellstern: That’s, then you, you, they, they tend not to, uh, be so focused on the technology. Right, right, right. And then there’s the people that built to keep, right, right. And you could, if you can see, they, that was their intention. And then they [00:28:00] ended up having to divest anyway. Then, you know, that they, they, they probably did, did a little bit more work on the technology side.

Which

Allen Hall: one’s more successful? Build to sell or build to keep

Lene Hellstern: build, to keep

Allen Hall: built, to keep has better power production, more revenue,

Lene Hellstern: less uh, downtime.

Allen Hall: Less downtime. Yeah. Because they’ve done their work upfront and many

Lene Hellstern: of them Yes. Have have done it. Yeah.

Allen Hall: Mm-hmm.

Lene Hellstern: So, but, but developers can still do, uh, build to sell.

Sure. But then they need someone with the technol technological glasses to come in and help.

Allen Hall: Sure, sure. But that’s where PEAK wind comes in, because. You carry those people on your staff, you, your PEAK wind’s full of experts.

Lene Hellstern: We would love to, yes.

Allen Hall: So that you can immediately tap the group of experts about the different aspects of this new development.

Yeah. From training to warranties to technology to just generally how an OEM performs and Yeah, but it’s

Lene Hellstern: also, it’s the technology [00:29:00] commercial finance, right? Bingo, finance. Yeah. They go, they go together. Right, right. It’s not a. Enough to have a brilliant gearbox that can last a hundred years if you only need it for 35.

Right. That’s true. And you paid a fortune. Right. That true. That’s just not a good business case.

Allen Hall: Right. And there are turbine manufacturers that have that model that do do that still. Yeah. Yeah. This is fascinating and I, I appreciate your time. Every time we talk, I just get more in depth of what is happening and, and where we can get better as an industry.

Yeah. And that’s what PEAK wind is all about. Yes,

Lene Hellstern: but we are really good already. We just need to get, we are good. Better. Yeah. Yeah.

Allen Hall: We do need to get better. And we do, I think we do need to take a pause.

Lene Hellstern: Yeah.

Allen Hall: So how do people get a hold of PEAK wind and to tap your expertise and attack, to bring in the expertise of your team?

Lene Hellstern: Well, we have a, a webpage, uh, where you can contact us through, or, uh, LinkedIn. I am on LinkedIn, so feel free to send me a, a message. Um. [00:30:00] So, and reach out to us and we would love to help. We also have a, we have offices in Boston and uh, uh, Texas. Uh, we also have Oh, around the world. Yeah. Canada. So Taipei, yes.

Yes. Re and

Allen Hall: congratulations. I think you just won a, was it in Taiwan? Uh, an offshore site Yes. That you’re gonna be operating or managing Meow.

Lene Hellstern: Yeah.

Allen Hall: Yes. Congratulations on that. Thank you. That’s very exciting. That’s

Lene Hellstern: my lovely C in asset management. Yeah.

Allen Hall: Very nice. Yes. So Lene, thank you so much for being back on the podcast and we have to have you back on again ’cause there’s so much to talk about and win.

And it’s great to talk to someone who has been around and has seen it and has done it. Uh, it’s, thank you for having, it’s such a tremendous learning experience.

Lene Hellstern: It was a pleasure. Thanks.

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North Carolina needs more certainty before committing to an expensive new gas plant

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Despite massive uncertainty across the economy, Duke Energy is plowing ahead with its plan to build new fossil gas-fired power plants to serve data center, manufacturing, and other large customer load that may not even show up. Duke has asked the NC Utilities Commission for permission to build a combined-cycle (CC) gas plant in Person County, North Carolina, at the site of Duke’s Roxboro coal plant.

SACE has argued against the need for this gas power plant in the Certificate of Public Need and Necessity (CPCN) docket, submitting testimony to the Commission on Monday, June 9, 2025. Here’s a summary of that testimony (prepared by Synapse Energy Economics, Inc.), which explains what this all means for Duke’s billpayers, and how Duke can make changes within its control to protect customers and reduce pollution. These recommendations include:

  • Not approving this new gas power plant because the risks that it will increase bills are too high. Instead, Duke should improve the processes that are holding back lower-cost renewables and storage, then use renewables and storage to meet new load.
  • Instead of approving this specific gas plant, the Commission should order Duke to use an all-source procurement process to determine a portfolio of flexible assets that can meet the utility’s needs based on real-world costs.
  • In the event the Commission approves this gas plant, it should protect customers from high bills due to volatile gas prices by instituting a fuel cost sharing mechanism for the fuel costs spent to run this plant.

Duke Doesn’t Need this Risky Gas Power Plant

Duke’s claim that it needs this fossil gas power plant is based on outdated analysis. In this CPCN docket, Duke relies on its 2023 Carbon Plan Integrated Resource Plan (CPIRP) modeling and the CPIRP supplemental update and analysis filed in January 2024. The world has changed dramatically since then, and it is important that the Commission review the latest information before approving expenditures that will impact customer bills for decades.

Duke’s load forecast – once based on steady, predictable growth – is now subject to significant uncertainty as 1) data center developers look around the country for the best deal and the fastest interconnection to the grid and 2) manufacturers announce projects and then pull back as political uncertainty changes the economics of those projects. Under Duke’s current rate structure, prospective companies and site developers do not need to commit much money to become part of Duke’s load forecast. They have very little “skin in the game,” and Duke currently does not have policies in place to change this. If the Commission allows Duke to build an expensive fossil gas plant for load that doesn’t materialize, Duke’s remaining customers will be on the hook to pay for it.

Duke’s own load forecast updates since 2023 show that there are wild swings in its predictions. In the Spring of 2023, Duke anticipated 8 new large load projects during its 10-year planning forecast period, requiring an average of 169 MW each. Then for Fall 2023 (the supplemental update filed in January 2024), Duke anticipated 35 projects requiring an average of 111 MW each. In Summer 2024, Duke changed its forecast again, projecting 39 projects requiring an average of only 103 MW. And in May 2025, Duke filed an update showing a reduction in the number of projects back down to 35 but a dramatic increase in average need – back up to 169 MW. Duke’s forecasts will continue to show swings up and down – both in the number of projects and megawatts – until Duke has policies in place that require more commitment from the companies that knock on its door requesting service. Duke also has not published information regarding the location of these loads – the latest forecast applies to all of Duke Energy in both North and South Carolina.

It is also important to know that that this gas plant isn’t needed to meet growing load from existing customers or to replace retiring coal plants (according to Duke’s own testimony). This gas plant is being justified by new manufacturing and data centers claiming they will be operating somewhere in Duke Energy Progress or Duke Energy Carolinas territory in North or South Carolina.

Even if the load shows up, this plant won’t be needed for long

Even Duke admits that it doesn’t “need” this fossil gas power plant for very long. These kinds of power plants, combined-cycle plants, are typically used about 80% of the time, i.e. they are “baseload” power plants. But even absent federal carbon regulations, Duke expects this power plant’s usage to decline significantly throughout its 35-year lifetime (from 80% in 2030 decreasing to 46% by 2040 and only 13% by 2050 onwards). As cheaper renewables and storage with zero fuel costs are brought online, they will displace this plant. Duke is proposing to build a giant power plant that will very quickly run less and less – but Duke’s customers will continue to pay for it until 2065—15 years past a state law requiring Duke’s generation fleet to be carbon neutral. This represents a significant change in how power plants are built and run, and this is not in the best interest of Duke’s billpayers. To add insult to injury, Duke hasn’t even procured all of the equipment needed to build this plant, so the costs could skyrocket even more than they already have since last year’s carbon plan proceeding.

Renewables are flexible, would protect customers, and would reduce pollution

Duke’s model only chose a gas plant to meet this capacity need because of limits Duke imposed on the model. Duke claims it cannot interconnect renewables and storage fast enough to meet this capacity need, but the reasons it cannot interconnect those resources faster are all within Duke’s control. As Synapse recommends, Duke needs to update its processes that are holding back renewables and storage from serving customers with low-cost and low-risk resources. These processes include interconnection and transmission planning.

SACE has been advocating for improvements to these processes for years, and Duke has made changes to both its interconnection process and transmission planning. Duke was one of the first utilities in the Southeast to implement cluster studies in its interconnection process, and it is in the midst of the first scenario-based transmission planning exercise in the region. But is there evidence that these updates have helped if Duke continues to limit solar and storage in its future resource modeling? Given the much quicker interconnection process recently demonstrated in Texas, this raises the question of how hard Duke is really trying to streamline renewables interconnection.

Modular, flexible resources such as wind, solar, and energy storage can be adjusted in quantity based on market conditions. As our testimony from Synapse states, “This modularity, combined with the fact that solar and wind have zero exposure to fuel price volatility once they are constructed, makes these resources particularly valuable in the face of trade tariff uncertainty.”

The bottom line is that the Commission needs a lot more certainty about load growth and costs before committing Duke’s billpayers to any type of large fossil gas power plant. We simply do not have that now.

The post North Carolina needs more certainty before committing to an expensive new gas plant appeared first on SACE | Southern Alliance for Clean Energy.

North Carolina needs more certainty before committing to an expensive new gas plant

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Ultimate Guide To Understanding Every Type Of Solar Panel

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Are you thinking of switching to solar but feeling overwhelmed by the wide range of panel options available in the market? 

You’re not alone, as many others feel the same way. 

In a sun-drenched country like Australia, where electricity prices seem to climb every year, more households are turning to solar as a smart, sustainable solution.  

The reason for this energy transition is apparent: harnessing clean, renewable energy gives you energy freedom, saves you costs on electricity bills, and reduces your reliance on fossil fuels, lowering your carbon footprint.   

Moreover, solar panels are not only good for the planet; they’re an investment for your future!  

But with so many types of solar panels, how do you know which one is right for you? 

  • Which panels perform best in Australia’s diverse climate?
  • What type suits your roof, your budget, and your energy needs?
  • And most importantly, are they really worth the cost? 

Well, in this comprehensive guide, we’ll explain the above questions and everything you need to know about solar panels in Australia.  

From solar panel types to benefits and efficiencies, this ultimate guide on all types of solar panels in Australia will help you find the most suitable panels for your home and financial needs. 

So, tag along to learn more details!  

What Are Solar Panels? | Breaking Down the Power of the Sun!

Let’s begin by addressing a very basic question: What is a solar panel, and how does it work? 

A solar panel is a device that converts sunlight into electricity using photovoltaic (PV) cells. Instead of burning fossil fuel, these different types of solar panels generate clean, renewable energy with Australia’s abundant sunlight.

How Solar Panels Work: A Simple Breakdown!

At the core of every solar panel, there is a set of photovoltaic (PV) cells. These cells are responsible for converting sunlight into usable electricity.  

When sunlight hits these cells, it excites electrons within the silicon-based material, creating an electric current. This current is then captured and converted into alternating current (AC) through an inverter, making it suitable for household or commercial use.  

However, solar panels cannot store energy for later use. Therefore, you might need to add battery storage to keep your home illuminated at night or during low-light hours. 

Are They Worth It for Australians?

Solar panels are generally a smart investment for most Australians due to the country’s high solar exposure, government incentives, and rising electricity costs.  

With abundant sunshine, households in most Australian cities can generate a significant portion of their electricity needs from solar. This energy switch can be a significant key to reducing power bills while enhancing grid stability. 

For example,  a 6.6 kW solar system can save households $1,000–$2,500 per year, depending on usage and feed-in tariffs. They can reduce your power bills by up to 70% 

Moreover, the federal Small-scale Renewable Energy Scheme (SRES), energy-saving schemes and various state rebates and incentives significantly reduce the upfront cost of solar systems.

So, with all these long-term savings, generous incentives, and positive environmental impact, solar panels offer a sustainable solution, making them a worthwhile financial and environmental investment for all.  

What Are the Most Popular Types of Solar Panels Available in Australia?

types of solar panels

Australia’s strong solar market offers various solar panel options tailored to different needs, budgets, and property types. Homeowners can access high-quality solar technologies from both local and international manufacturers, creating a global bond.  

However, instead of making a blind choice, it’s wise to understand the different types of panels, as each has different efficiency, durability, and cost advantages.  

So, before moving further, let’s have a glimpse at the most popular types of solar panels currently available in Australia:  

Monocrystalline Solar Panels: Premium Efficiency and Longevity

Monocrystalline solar panels are the most efficient type of solar panel. They are made from a single, pure crystal structure, which allows electrons to move more freely, resulting in higher efficiency.   

These panels are easily recognizable by their dark black color and rounded edges. While they are more than other types, their high efficiency and longevity make them a great investment. 

What are the Pros? 

  • High performance in low-light and high-temperature conditions. 
  • Sleek, modern look. 
  • Lower long-term cost per watt. 
  • Best for homeowners with limited roof space.  
  • Incredible longevity and efficiency.  

Talking about Cons: 

  • Monocrystalline panels are expensive. 
  • The manufacturing process results in silicon waste. 

Polycrystalline Solar Panels: Reliable and Cost-Effective

Polycrystalline solar panels are made from multiple crystal structures, which gives them a blue hue with a speckled look.  

They are less efficient than monocrystalline panels but are also less expensive. These panels are great for those with ample roof space and a tighter budget.  

What are the Pros? 

  • More affordable than Monocrystalline panels. 
  • Leaves less waste during production. 
  • Offer decent performance for residential use. 
  • Easier manufacturing process.

Talking about Cons: 

  • Less efficient. 
  • Require more space than Monocrystalline panels. 
  • Lower the aesthetic appeal of homes. 

Thin-Film Solar Panels: Lightweight and Versatile

Thin-film solar panels are the most affordable but least efficient type, with energy efficiency ranging from 7% to 18%. They are made by layering photovoltaic materials onto a surface.  

These panels are flexible, lightweight, and ideal for industrial and commercial use in Australian landscapes. 

The types include: 

  • Cadmium Telluride (CdTe) Panels 

Cadmium telluride is the most common thin-film panel, constituting about 5% of solar panel sales. These panels can achieve an efficiency rating of 9% to 15%. 

They are made from cheaper, toxic materials such as cadmium telluride and cadmium sulphide, which can pose environmental and health risks. 

  • Amorphous Silicon (A-Si) Panels 

Amorphous silicon panels use a different technology that makes them very flexible. Instead of using crystalline silicon wafers, these panels use a thin silicon strip with a rubber-like texture. 

These panels are incredibly lightweight, versatile, non-toxic, and cheap, but have a low efficiency rating of about 7%. 

  • Copper Indium Gallium Selenide (CIGS) Panels 

CIGS panels are the most efficient thin-film panels available. They are composed of copper, gallium, indium, and selenide layers placed on a base of steel, glass, plastic, and other materials. 

These panels can be installed where standard panels cannot fit. They have a high enough efficiency rating of 12% to 15%.  

Bifacial Solar Panel: Power from Every Angle!

Bifacial solar panels can generate power from both sides, capturing sunlight that hits the front of the panel and light that reflects onto the back. It’s like double the sides, double the Power! 

This can increase energy production by up to 30%. They are ideal for ground-mounted solar systems or buildings with reflective roofing.  

Concentrated PV Cell (CVP)

Concentrated PV cells are the most efficient type of solar panel available today. They use lenses or curved mirrors to focus sunlight onto a small area of high-efficiency solar cells.   

However, they require direct sunlight and a cooling system to function effectively. They are more suitable for large-scale commercial projects in sunny locations.   

Solar Panel Types by Efficiency and Longevity: A Detailed Comparison

Type Efficiency Lifespan Perfect for
Monocrystalline 18–22% 25+ years Homeowners with limited roof space or those prioritizing efficiency and longevity.
Polycrystalline 15–17% 20–25 years Budget-conscious users with ample roof space.
Thin-Film 10–13% 10–20 years Large buildings, factories, and unconventional surfaces like car roofs or windows.

5 Factors to Look for While Installing a Solar Panel in Australia

Choosing the right panel is just half the job, where installation quality and system design play a huge role in overall performance. 

So, here we’ve listed what to consider before installing a solar panel on your property:

1. Sun Exposure and Roof Orientation

Proper sun exposure is a significant factor for maximizing energy production. In Australia, a north-facing roof typically captures the most sunlight.  

Also, ensure your roof is free of large trees, chimneys, or other shading.

2. Solar Panel Efficiency

Higher solar panel efficiency means more power, which ultimately leads to faster return on investment (ROI). This is especially important if your roof area is limited or you live in a rented property.

3. Durability and Warranty

Look for panels that offer 25-year performance warranties and 10–15-year product warranties.  

These warranties can provide long-term peace of mind and potentially save you significant repair or replacement costs.  

4. Installer Credentials

Once you decide to install solar, choose Clean Energy Council (CEC) accredited installers.  

They’ll help make sure your system follows Australian rules and let you know about rebate eligibility criteria.  

5. Proper Installation and Aftercare

Lastly, the installer will mount the solar panels on your roof and connect them to a solar inverter.  

After the installation, the system will need to be inspected by a certified electrician. Then, a monitoring app will track how much electricity your system produces and how much you use.

Some Other Hidden Factors That Might Impact Your Solar Setup!

While planning a solar installation, most people focus on the obvious elements like panel type, system size, and cost.  

However, beyond these core considerations, there are several lesser-known factors that can quietly influence the efficiency, longevity, and overall success of your solar setup.   

This includes: 

  • Hail Rating of the Panel 

This rating indicates how well solar panels can withstand hail impacts. Panels are typically tested by firing ice balls at them to simulate hail.  

A higher hail rating means better durability in hail-prone areas, reducing the risk of cracks and performance loss. Crystalline panels can handle hail hitting speeds up to 50 mph, while thin-film panels are thinner and less resistant. 

  • Temperature Tolerance of the Panel 

Solar panels become less efficient at high temperatures. Temperature tolerance, often measured as a temperature coefficient, tells you how much performance drops per degree above 25°C.  

Lower coefficients mean better performance in hot climates. So, here are the temperature coefficients for different panel types: 

    • Monocrystalline: -0.3% to -0.4% / °C  
    • Polycrystalline:  -0.4% to -0.5% / °C 
    • Thin-film: -0.2% to -0.3% / °C 
  • Fire Rating of the Solar Panel 

Solar panels and mounting systems must meet fire safety standards. The fire rating is usually classified in Class A, B, or C, reflecting the system’s resistance to fire spread and ignition.  

Class A is the most fire-resistant, which is crucial in wildfire-prone regions like Australia. 

  • Light-Induced Degradation (LID) 

LID (Light-Induced Degradation) is a common issue in crystalline solar panels, where they lose about 1–3% of their performance during the first few hours or days of sun exposure.  

It happens when sunlight reacts with tiny amounts of oxygen left in the silicon during manufacturing.  

This reaction slightly disrupts the silicon structure, reducing the panel’s efficiency. 

How to Choose the Right Solar Panels for Your Property?

Every home has different setups, so the solar panel installation process also varies from home to home. Here’s a stepwise checklist to help tailor the perfect setup: 

Step 1: Assess Your Energy Needs 

Before choosing solar panels, look at how much electricity your home uses. Check your electricity bills to calculate your average daily usage in kWh 

If you’re planning to expand or add things like an electric vehicle or a home addition, consider how that might increase your energy needs in the future. 

Step 2: Evaluate Roof Size and Position 

In Australia, your roof’s position and condition matter greatly for solar energy generation. Therefore, while installing the panel, you should consider: 

  • Roof orientation, as south-facing roofs typically capture the most sunlight.
  • Proper tilt and shading for minimal shading from trees, chimneys, or nearby buildings.
  • Larger roofs offer more installation space, while older roofs may need repairs, so check the roof size and condition first. 

However, if you have limited space, go for high-efficiency monocrystalline panels, and Polycrystalline might be a better value for plenty of space. 

Step 3: Set a Budget 

Solar Power System prices vary widely from place to place. But with our 440W Tier-1 Panels and 5kW Wi-Fi Inverter in a 6.6kW Solar Power System, you can enjoy the benefits of solar power without a hefty price tag. 

  • For 6.6 kW System: 

Original Price starts from $3,690.00 

Cyanergy’s VIC Offer Price starts from $890.00 

  • For 10.12kW System 

Original Price starts from $5,770.00 

Cyanergy’s VIC Offer Price starts from $2,970.00 

  • For 13kW System 

Original Price starts from $7,130.00 

Cyanergy’s VIC Offer Price starts from $4,330.00

Step 4: Find a Trustworthy Installer & Factor in Rebates 

Federal STC rebates and various state-based incentives can save you thousands off your upfront cost, so look for a certified, experienced installer who can help you claim them.

So, Which Solar Panel Type Should You Use?

Honestly, there is no specific answer to this question. The panel type and effectiveness depend on several factors, including your installation location, budget, and aesthetic preferences.  

However, here we’ve shared a quick guide based on different situations to make your purchase decision easier:  

Different Scenarios Recommended Type
Limited roof space or rental property Monocrystalline
Tight budget with big roof space Polycrystalline
Flexible portable solutions Thin film
Need long-term high output Monocrystalline
Off-grid or rural installations Thin-Film or Hybrid

Some of the Best Solar Panels in Australia (2025 Edition)

Best Solar Panels in Australia

When choosing the best solar panel brands in Australia, performance, durability, and warranties matter most. 

  1. SunPower
    • Efficiency: Up to 22.8%
    • Warranty: 40 years (industry-best!)
    • Why Choose: Premium performance and extreme durability
  1. REC Solar
    • Efficiency: Up to 21.9% 
    • Warranty: 25 years
    • Why Choose: Excellent value for performance, strong Australian support
  1. Q CELLS
    • Efficiency: Up to 21.4%
    • Warranty: 25 years
    • Why Choose: Robust tech with good performance in varying light conditions
  1. Jinko Solar
    • Efficiency: Up to 21%
    • Warranty: 25 years 
  1. LONGi Solar
    • Efficiency: 20%
    • Warranty: 25 years
    • Why Choose: Solid mid-range performer, good balance of cost and quality 

For any queries, contact Cyanergy. Here, our solar experts will provide the best solution based on your preferences.  

Remember, with the right panel type, a trusted installer, and a bit of planning, you can enjoy decades of clean, affordable electricity. 

Your Solution Is Just a Click Away

The post Ultimate Guide To Understanding Every Type Of Solar Panel appeared first on Cyanergy.

Ultimate Guide To Understanding Every Type Of Solar Panel

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Wind Turbine Monitoring: Fibersail’s Predictive Maintenance Could Save Operators Billions

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Weather Guard Lightning Tech

Wind Turbine Monitoring: Fibersail’s Predictive Maintenance Could Save Operators Billions

Wind turbine blade failures represent the largest ongoing expenditures facing wind energy operators, with over $5-6 billion spent annually on unplanned repairs. What if wind turbine monitoring detected blade damage before it becomes catastrophic – and could give operators a clear strategy to prevent failure?

That’s what Fibersail, based in Portugal, with offices in the Netherlands, has developed with its innovative fiber optic sensing system.

Fibersail CEO Carlos Oliveira joined us to discuss why they developed this new turbine monitoring system, what they learned along the way, and how it’s working for wind farms around the world.

You can listen to the interview here or read the highlights below.

The Future of wind turbine Monitoring

As the wind industry continues to scale and turbines grow larger, the need for advanced monitoring systems has increased as well. Fibersail’s fiber optic technology represents a fundamental shift from reactive maintenance to predictive maintenance, potentially saving the industry billions while improving the reliability of renewable energy generation.

Wind Turbine Monitoring is a Billion-Dollar Problem

Most operators face the same stark reality: traditional monitoring systems simply aren’t equipped to handle today’s massive turbine blades. As Oliveira put it, “We are building bigger and bigger blades, using old technology. It does not work.”

Where turbines once showed problems after 5-8 years of operation, today’s operators routinely see major blade issues within the first year or two of operation—sometimes even during the warranty period. This dramatic change has led to some major companies recognizing billions in losses due to blade-related issues. It’s conceivable – realistic, even – that if this trend continues, it could put the entire wind industry at risk.

Why Go Beyond Traditional SCADA Systems?

Most wind turbines today rely on SCADA (Supervisory Control and Data Acquisition) systems for monitoring, but they weren’t designed to detect the structural issues that lead to blade failures. Fibersail’s fundamentally different approach brings advanced sensing technology directly to the blade structure.

The company’s fiber optic technology provides real-time data about blade behavior that simply isn’t available through conventional monitoring systems.

The Shape-Sensing Revolution

Fibersail’s innovation is its unique “shape sensing” technology. The concept originated from measuring sailboat sails and has evolved to monitor wind turbine blades—essentially treating each blade as a “rooted sail.”

Here’s how it works:

  • Fiber optic sensors are installed directly inside the blade, running from root to tip
  • The system monitors the blade’s shape in real-time, detecting minute changes that indicate structural issues
  • Dual validation occurs by monitoring both shape changes and frequency variations
  • All complexity is encapsulated in a robust system that field technicians can easily install

A Pragmatic Implementation Strategy

Ideally, a sensing system that is built into the blade would be an OEM integration, but Fibersail knew that would delay market entry, possibly for years, while operators and quite possibly the industry – ran out of money and out of business.

Rather than waiting for OEM integration, then, Fibersail began working directly with wind farm operators—the ones who face the immediate financial impact of blade failures.

“The owner-operators are the ones who have the problem to solve,” Oliveira explained. And by working directly with wind farming operations, Fibersail is better able to gather real-world data to prove how the sensing system saves blades, and money. The strategy is paying off.

The company is currently collecting field data from multiple installations, with promising early damage detection and damage propagation projects underway. This real-world validation is crucial, Oliveira emphasized, saying, “Nothing is as valued as the data from the field.”

installation data from Fibersail

From Data to Actionable Intelligence

Perhaps most importantly, the data Fibersail provides is not just graphs and charts, but actionable intelligence. Oliveira calls the solution “elegantly simple.” When the Fibersail system detects a problem or potential damage propagation, it sends an email alert to operators, allowing them to prioritize their limited maintenance resources effectively, and to focus on turbines that need immediate attention, while allowing others to wait for scheduled maintenance.

Blade Manufacturing: Variations Happen

Unfortunately, in working with wind farm operators, Fibersail has seen firsthand the frustrating reality of blade manufacturing variability. While blades are theoretically identical when they leave the factory, manufacturing tolerances mean each blade is slightly different. Add a few years of operation, repairs, and patches, and operators end up with what Oliveira colorfully describes as “Frankenstein turbines.”

This variability makes traditional numerical models inadequate for predicting real-world blade behavior – and it highlights the need for actual sensing technology.

Overcoming Installation Challenges

One of the biggest hurdles in the industry is navigating warranty restrictions and service agreements that can prevent operators from installing aftermarket monitoring systems. Fibersail positions itself as a solution provider for the entire industry, not just for the owners and operators, but also working with manufacturers and developers.

The company aims to create three-way partnerships between Fibersail, the customer, and the OEM when possible. The entities are more likely to work together when they see how the technology benefits all parties, by reducing costs and improving reliability – always a key to navigating warranty issues.

Oliveira noted that Fibersail understands its customers need to comply with strict cybersecurity requirements, which is simply a necessity in today’s complicated energy industry.

Tailored Solutions at Scale

Fibersail offers a modular product line that can be customized based on customer equipment, site conditions, and other operationall factors, including –

  • Basic load sensors for customers needing fundamental load data
  • Shape sensors for early damage detection
  • Hotspot sensors for comprehensive damage monitoring
  • Integrated systems combining multiple sensing technologies

Because of the company’s flexible offerings, customers can start with a basic monitoring system and add complexity as needed.

Expanding into Offshore

While Fibersail is currently focused on onshore installations, the company is expanding to offshore applications, with the first Fibersail offshore installation in the Netherlands planned for this summer. In the more challenging offshore environment, the company expects that the return on investment will be even greater.

For More Information

Learn more about Fibersail’s innovative blade monitoring technology at fibersail.com or connect with the company on LinkedIn for the latest industry insights and project updates.

Fibersail CEO Carlos Oliveira

https://weatherguardwind.com/wind-turbine-monitoring-fibersails-predictive-maintenance-could-save-operators-billions/

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