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Siemens Gamesa, Vestas, Ørsted Updates: Finances, Fallen Rotors, and Offshore Wind Outlook

This week we analyze recent news from Siemens Gamesa, Vestas, and Ørsted, including financial struggles, layoffs, and plans to regain profitability. The episode also covers offshore wind manufacturing expansion in the U.S., a fallen wind turbine rotor in Norway, and the need for better data sharing among wind farm owners and operators. Plus, if you’re attending ACP O&M in San Diego, sign up for the IntelStor event!

Sign up now for Uptime Tech News, our weekly email update on all things wind technology. This episode is sponsored by Weather Guard Lightning Tech. Learn more about Weather Guard’s StrikeTape Wind Turbine LPS retrofit. Follow the show on Facebook, YouTube, Twitter, Linkedin and visit Weather Guard on the web. And subscribe to Rosemary Barnes’ YouTube channel here. Have a question we can answer on the show? Email us!

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Joel Saxum: So Allen is in Denmark at the Leading Edge Symposium DTU in Roskilde there with a lot of really smart people talking about leading edge erosion issues. What are the newest protections out there? What kind of projects going on in the world? From our side of view, how does aerodynamics leading edge roughness affect lightning?

A lot of really cool things going on there. Of course, DTU is always doing great work. But that’s where Allen is today. So this week I’m going to try to be my best Allen. I’m Joel Saxum, the chief commercial officer of Weather Guard Lightning Tech. And I’m here with international renewables expert, Rosemary Barnes.

Plus, wind energy economics and data guru Phil Totaro from IntelStor. This is the Uptime Wind Energy Podcast.

So speaking about offshore wind in the United States and how the IRA bill is interacting and if it’s kicking off manufacturing facilities or what’s actually happening on the ground, today there was an announcement by US Forged Rings Inc. It’d be the USA’s only integrated one stop shop manufacturer for offshore wind towers and steel forging.

What they released today in an article was, or in a press release was, the fact that they’re going to have two factories up and running on the east coast. One by 2026, one by 2027. And they’re going to work together. To build these large scale steel infrastructure that we need for offshore wind in the U.

S. So one of one of the factories is going to output towers. They’re saying a hundred towers per year with a 35 foot diameter on them and the other factory that’s going to be completing 2027. It’s for forging and ring rolling, and they can do up to 40 feet in diameter. So what this will do is be able to help the U.

S. market create its own transition pieces, its own, bearing races, its own caps for the towers and whatnot. But Phil, what are the larger reaching implications of this press release?

Philip Totaro: It’s extremely good for the offshore wind market where, a company is looking to obviously take advantage of the 45x manufacturing tax credits.

What’s interesting about this, though, is that in addition to this serving the offshore wind market, assuming that this factory exists, we don’t actually have a lot of particularly forging capabilities in the United States for anything above, let’s say, like a megawatt onshore turbine. We usually have to import a lot of that stuff from Europe.

Even Asia doesn’t have the, a full capability to do, enormous 6, onshore turbines. A lot of that they’re actually getting from Europe as well. Surprisingly, to, to most. The fact that this, these factories will exist, and, the tower factory with, it’s going to start off at 100 units a year and they said that it’s going to potentially expand to 200 units a year.

We’ll see. Maybe some of those units will actually be dedicated to to some onshore wind turbines as well. If we can get the offshore market really going, then they’ll be fully utilized in building offshore towers and transition pieces. But there is that possibility that we can leverage them for an expansion in the onshore market too.

Joel Saxum: Yeah, some interesting stuff here in their press release, they also are talking about being able to use some of the capabilities that they’ll have for offshore floating turbines, because if you have a spar design or other kind of designs, they need the large tubular pieces, right? This could enable the floating offshore wind in the US.

Of course, we’re looking at that on the West Coast. With the deeper water out there and there is some leases floating around out there on the east coast for further out past what we’ve been talking about lately into deeper water. Also with that forging and ring rolling factory on the other side you’re looking at yaw rings, pitch bearings, main shaft bearings and other large components.

The another thought I have here, Phil or Rosemary for that matter as well. Do you think that the capabilities of this factory could be used for other things than offshore wind, or will it be specifically just offshore wind? Could it be used for other large industrial facilities?

Philip Totaro: I don’t know enough about it to say what else this could be used for, and frankly, why, if we have oil and gas fabrication facilities, why they aren’t Doing something for offshore wind and we’re just like converting something that already exists for oil and gas Maybe they don’t need anything that big.

I don’t but we’ll make use of these factories I’m telling you like whether it’s offshore wind onshore wind, whatever. We’ll make use of these factories.

Joel Saxum: I think the difference there in oil and gas is when you have an oil and gas jacket or Other infrastructure. It’s so specialized That it’s a one off, right?

They’re not building a factory to make these things. They’re either ordering that one piece or that two pieces or whatever it is from somewhere that can already complete it, or they’re piecing them together. I’ve seen a lot of jacket foundations that are not rolled steel. They’re pieces. That are all welded together, right?

So they build a facility and do that custom fab. Not the case when you’re going to scale.

Rosemary Barnes: I think that the unique thing about this facility is the size, like the large diameters that they can do, which means I can do wind turbine towers. And not familiar with absolutely every single thing that’s made out of steel, but I don’t think that anything else needs those really large diameters.

Obviously if you’ve got a factory that’s big enough to make really big stuff, it could make smaller stuff if it wanted to, but yeah, that isn’t such a big challenge and there’d be other competitors that are already filling that need. So I’m guessing it’s going to be fairly specialized.

Philip Totaro: Yeah, the only thing I would think of might be pressure vessels for any various number of applications. The only thing is that’s also a specialized. Fabrication capability, so I’m not quite sure if they’d actually be able to, again I think these factories are intended to be offshore wind.

There is obviously a possibility, as I mentioned, of being able to leverage it for larger onshore wind machines as well either for domestic consumption or frankly, even an export market, because when you contemplate. We could be fabricating parts here in the U. S. for export to China, for instance.

That is a possibility. Or even, actually, Australia, because there’s a lot of projects in Australia that are proposing six and seven and eight megawatt turbines. Unless they’re gonna make it a point to, to build their own localized fabrication facilities. Who knows we could be we could be making some parts for them.

Rosemary Barnes: Yeah, I think I know that there’s plenty of people that have in mind that is a really good entry point into wind turbine manufacturing. It’s 1 of the easier things and. Australia already makes some towers some parts of towers at least. So it’s, not such a stretch that we would move up to that.

We do have a steel industry. It’s not what it used to be, we’ve got all the iron ore. There’s a lot of work now to move towards processing that into steel in Australia and then. Yeah, it’s already I’m not the only one that’s been saying for a decade or more how crazy it is that we take our iron ore, send that to China, they turn it into steel, and then, whatever else they make from the steel and then send that back to us.

It’s. It’s not good for Australia, keeping the real value from our minerals in Australia, the digging up of the mineral is, like the least valuable part of that whole process, values added all the way along through the manufacturing chain. And yeah, aside from it being economically stupid, it’s also environmentally stupid because, obviously if you send the unrefined steel over, if you’ve got like 50% concentrated iron ore, and when that comes back, you’ve got double the volume that you’ve got to send over there compared to what comes back.

So you can save a lot in shipping and. Yeah, so we are, we should have been doing it from the start, but I think, the whole world was really into globalization and just low costs at any non financial costs. We were prepared to, give up nearly anything if the cost of steel or whatever other material was lower and the whole world’s moving away from that now and slower than I would have liked, but Australia has all the pieces in place to.

Like a wind turbine tower should be the very easiest thing that we should definitely be manufacturing in Australia. And yeah, I am hopeful that we will within a few years.

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Joel Saxum: So news out of Denmark today, guys. Ørsted is suspending its dividend and cutting some jobs as it changes how it addresses offshore markets. So the wind developer says it needs to create a leaner and more efficient company. This is the words from Mads Nipper today. We’ve prioritized projects within our portfolio and are implementing significant changes in our business, including revising our operational model to reduce risks.

We now present a robust business plan with an uncompromising focus on value creation. Plan to install more than double our current installed capacity of renewable energy by 2030. The thing I like here that he said and I haven’t dug completely into it yet is that we are presenting a robust business plan.

This is something that we haven’t heard of some other players in the wind industry. I. e. Siemens, Gamesa, and whatever that they’re doing, what is their plan? Ørsted has one now. Phil, what does this mean for Ørsted going forward?

Philip Totaro: As they indicated, they’re getting rid of some of the fluff, let’s call it.

Which is going to include some of the Power to X projects that they had on the menu. Some of the hydrogen production, et cetera, et cetera, and focusing on core business, focusing also on core markets. And on. Doubling down in their their view on, offshore wind again, core European markets but also Taiwan and they’re obviously going to continue what they’ve been trying to do in the U.

S. South Fork is still, on on track for coming online this year. And we’ll see what happens with some of the other projects that they’re still pursuing and involved with. They may end up still divesting some of the the projects here in the U. S. Eversource also wants out if both project developers are looking to get out, then that’s potentially an opportunity for someone else to get in.

I think again, as we’ve talked about, it is a good thing that they present a a business plan that provides investors and shareholders more confidence, because that’s the key as far as what was lacking, and it’s we do liken it to other companies like Siemens Gamesa, Ørsted just came out a few months ago and said we have a problem.

But they didn’t really say we have a solution, too, and here’s what it is. It’s just, All they did was diagnose the fact that they have issues. And now they’ve at least put pen to paper and said, Alright, we, here’s how we’re gonna dig ourselves out of the hole. It’s unfortunate that not only the 800 jobs that they’re going to be cutting, but their long time chairman also stepped down as a result.

And, as we’ve also talked about, one would presume that Mad Snipper’s job also isn’t safe, but they’re at least leaving him in his current position until this can, this kind of transition can occur, and then they’ll find someone else to champion the new era of Ørsted.

Joel Saxum: Yeah, interesting here.

They’re the market that some of their plan. Okay. Phil, you mentioned it. They’re cut 800 jobs. They have about 9, 000 people globally. So that means that just under 10 percent of their staff is looking for pink slips. That’s not the best way to be, but. It’s reality. And the markets that they’re going to withdraw from our Norway, Spain and Portugal.

Now, Norway, Spain and Portugal for the most, a lot of that is floating to my knowledge. They’re not as advanced as the projects that they operate right now in the North Sea. But it is interesting as well. The with the chairman stepping down. So Thomas Tuna Anderson has been there for 10 years.

He’s exiting that role. And also we had, this past fall, Daniel Lerup, the chief operating officer. Or the finance chief and then Richard Hunter, the chief operating officer left as well. So there has been, we have talked about how long will Mads Nipper keep his job. But there has been a lot of changes from the board of directors all the way down.

And we’re all hopeful that Ørsted comes out of this thing. A shinier new product because them being healthy is good for the offshore wind energy market as a whole Rosemary, any thoughts on this Ørsted move and them pulling back a little bit, what it means for their future.

Rosemary Barnes: Yeah I think that they had the right idea with their strategy to, get in early with the U S market. A lot of people had that idea and I think that’s why we saw such a, like a feeding frenzy for some of those early auctions. Everybody wanted in, and they got in, but I don’t think people anticipated how I don’t know, wishy washy, is that the right term? The environment in the U. S. was?

Philip Totaro: Yes. Yes, it is.

Joel Saxum: Yeah, it’s perfect.

Rosemary Barnes: Yeah, I think it’s a huge cultural difference between Denmark and the U. S. And I’ve lived in both countries, the U. S. just for one year back in. 20 years ago. So it’s been a while. But Denmark is characterized by just that they’ve got immense trust in, other people and in governments.

I think that they’re like the most trusting country in the world, or at least one of them. Which I think that they might as a, Danish company culturally. They might have been surprised that when you enter into agreements with governments that things don’t, there isn’t a lot of trust going back the other way, so I think that they might’ve been surprised by that relationship and so that the cultural clash might’ve been more than what they’re expecting. But I do still think that it’s the right move, but just that it was too soon. The U. S. isn’t actually ready for all of these European companies to come in and ramp up offshore wind really fast in the U.

S. We all wish that it was true and I wouldn’t have predicted these problems a couple of years ago, but here we are. But that said, I do like the company. It’s just such a great story of a company that went from being an oil and gas company that was literally in their name and now they’re a renewable energy company.

I don’t know if there’s any others in the world that have actually managed to do that. Like I am rooting for them, for the company. I actually, I have a note I sent a reminder in my calendar to buy some Austered stocks once this kind of settled down because it fell so far. And I don’t really believe that there’s anything wrong, anything much has changed with the fundamentals of the company.

I still haven’t done that yet. And just mostly out of forgetfulness, but it’s nice to say that they feel a little bit more because now I can get an extra couple of percent. Since they’re lower don’t take that as stock advice. If you looked at the, returns that I make in my portfolio, then you would certainly not come to me for stock advice.

But yeah, the size of the layoffs was interesting. What is it like nearly 10 percent of their workforce. And I will say. Denmark is brutal, absolutely brutal for stuff like that. People might have the wrong idea that, Denmark is Scandinavia, everybody’s warm and fuzzy. And you might have heard like Swedish people tell you how it’s impossible to fire anyone as culturally similar as Denmark is to Sweden.

It is just absolutely not like that in the workforce. They they call their system. Flex security, I think, like flexible security. The flexibility is just the ability to ruthlessly just slash their workforce by 10 percent for, they don’t have to give that much of a reason or be that generous even in their payout to the staff that they let go of.

But the security is that for Danish people, it’s quite it’s quite secure in the amount of unemployment money that you’ll get for quite a long time while you’re looking for work, as long as you I can’t remember the exact setup. I think you have to be a member of a union or something similar to it, some kind of insurance to get that.

But I will say as a foreigner it’s, there’s no, no security for you there as a foreigner. So all the foreigners that the international workers that got laid off, that’s yeah, that is just as brutal as it sounds. So yeah it, it’s good for the company though, that they can make a big change when they need to better that than that they, limp along for the next decade, trying to scrimp and scrape enough to recover, this way, hopefully they can.

Get it all done in one go and then move forward with the stuff that’s going to be profitable in the near term and have the strength there to get back into the U. S. When the country is ready for it.

Joel Saxum: Rosemary, I don’t want to make you feel bad about your delay in the stock price, but back in the fall, not too long ago, a couple, two, three months ago, when they initially, Hey, we announced these write downs and stuff, their stock dropped to about.

11 and 80 cents us. And it’s already back up to 18.

Rosemary Barnes: There you go. So this is why you shouldn’t trust me for investment advice. I’ve missed the boat. I’m also, I’m very, I’m lazy as well with my investing. I. I do it when it occurs to me. And yeah, I’m definitely not someone that’s looking up stock prices every day and making a lot of trades.

I buy something and then I hold it for, as long as I can.

Joel Saxum: So guys sticking in the financial realm of things, you’re gonna talk about Vestas for a little bit. So Vestas’ return to profitability, however, not going to give a dividend either. And for good reason, their dividend would have been minuscule based on what their profitability was, but they are back in black and their discipline is paying off is what they’re stating in their report for the year.

So I’ll give you some numbers here. They made a full year operating profit before special items of 231 million euros. Compared to a loss of 1. 2 billion euros the year before, so that’s a big turnaround. They adjusted the operating profit in fourth quarter, was 191 million euros versus a loss of 514 million euros the year before.

So they’re beating analysts, they’re doing a bit better. The guidance that they’ve given, Investors forecast revenue this year of 16 to 18 billion euros. And the analysts are looking at 17. So they’re right in that same window with what the, they believe will be. So Henrik Andersen, the CEO has stated continued geopolitical volatility, as well as slow permitting and insufficient grid build out across markets are expected to cause.

Uncertainty in 2024. So Vestas is getting back to better health. This is something that we’ve talked about for the last few years was going to take a little while to happen, but it’s great. However, this is the angle I would like to talk at this one with you guys about, do you believe that some of the downfall of what Siemens has going on and them stopping selling their certain platforms right now in the market has led to an increase in Vestas?

Philip Totaro: Modestly, I’ll say, Joel a lot of this getting the Vestas getting back to profitability has more to do with a recovery in turbine prices, because, as you may recall in prior years, even Vestas came out and said that the average price they were seeing. For turbines was about 700, 000 U.

S. per megawatt. And that’s taking into account, markets where you’re selling turbines for a million a megawatt, but also markets where you’re selling for 600, And so now the average price, according to our own numbers at Intel Store, we’re seeing much higher turbine sale prices for projects that were closed last year, including, a lot of the 18 gigawatts order book that they announced last year.

But they’re quoting much higher now they’re around 900, 000 a megawatt megawatt, if not a little higher now in terms of the price quotes that they’re offering at this point for projects which presumably would be delivered to in the next two to, to three years.

Yes, the downfall of Siemens Gamesa has allowed Vestas to go gain some market share in markets where, they would have been competing with megawatt platform. The only reason I guess I’m hesitating on it is because I feel like, Vestas would have already been leading that.

Those markets anyway because while everybody still thinks that Siemens Gamesa makes a solid product even prior to the quality issues it just wasn’t always the favored turban and I don’t know if that comes down to perception of performance, perception of bankability. The service offerings that, or the quality of the service offering that’s received by an asset owner and operator.

Yeah, there’s there, again good news for Vestas in terms of getting back to profitability. It seems like most of the cost increase that they’ve been able to incur. Or that they’ve had to incur as a result of commodities and raw material costs going up has been passed on to customers i.

e. project developers. That’s good. But again, even with them not issuing a dividend, I think it’s fine from the standpoint of the shareholders in the company who will anticipate getting back to a higher dividend once that. Can presumably occur later on this year.

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Joel Saxum: So guys, Siemens Gamesa staff in Aruzury, Navarra will go on strike. We’ve been talking about them possibly going on strike in Spain there for a while. And it sounds like one of the factories has actually pulled the trigger and made it happen.

So what they’re saying is Aruzury is the only center in Navarra that has not adhered to the corporate office agreement with Siemens Gamesa. which is a clear discrimination. It looks like it’s going to affect 62 workers at the plant that they’re going to basically shut it down. So what are the ramifications for this in a plant like that, Rosemary?

Rosemary Barnes: It’s It’s an interruption.

Philip Totaro: This is the sort of thing that, they’ll do this occasionally, Vestas has suffered from temporary factory shutdowns in Spain. GE even had protests, going back a few years, LM factories in Spain as well in the past.

It’s usually like a very modest and temporary interruption. It’s not anything that’s gonna like dramatically impact production per se. But it’s one of those things that it’s, this is like the fourth different location since, Siemens has announced that they’ve had these product quality issues.

This is like the fourth location that said that they’re gonna go on strike and so it’s just culturally, I think they’re just facing a challenge there to provide reassurance, not only to investors and shareholders, but to their own staff to say, look, we’ve got a plan for getting ourselves out of this.

But we all need to pull together to be able to do that. And, obviously these 62 people feel like they’re not being treated equitably.

Joel Saxum: And that so that plan, like we’re saying, Ørsted came out with the, Hey, here’s our plan. Siemens Gamesa has a plan, they’re calling it the Mistral.

Plan to address some of these issues within the inside there. So their, they’ve actually came out now it’s quarterly earnings time, right? We’ve been talking a little stock market, a little finances here. So Siemens energy different, of course, than Siemens Gamesa right now dragging Siemens energy down on their quarterly reports a bit.

It looks if you were to take the quick numbers from Siemens energy. The revenues to 2 billion euros for this past fiscal year but that comes with a loss of or a reported EBITDA, which is basically your loss after everything else you pull out of it, of a negative 900 million.

So pretty tough times to be in the Siemens Comesa finance department. But what is, how does that overall feel affect with Siemens, that if, when you take into consideration Siemens Energy as the parent and Siemens Gamesa looking like this, are they going to have to make some big moves to save this thing financially, Phil?

Philip Totaro: There’s still struggling with a couple of different things at the moment. It sounds like they obviously have their head around what the quality issues are. They haven’t quite effectively communicated that to investors and shareholders because they’re still clamoring for what exactly is the full extent of this?

And management came out even today when they released their numbers. And said, we aren’t expecting anything worse than what we’ve already told you to paraphrase which I guess is good from one perspective, but it’s also unsettling because, people want to either have confidence that you’ve, tied this off and we can move on, or, and get back to selling or it’s something where, oh we were, grossly or disproportionately over predicting what we were going to spend, the 5 billion loss that, that we were going to have, it’s actually not going to be 5 billion.

It’s only going to be 3 or whatever, and it’s oh, my God, that’s great to an extra 2 billion that, that we don’t have to waste on losses. That’s the sort of thing that investors shareholders want to see. And here And they’re still not seeing and hearing that from Siemens Gamesa management and that’s where I think we still have a problem here, they keep trying to provide assurances about the quality issues are, understood and are being dealt with, but again, even from that perspective, I think since the start of this whole thing, Siemens Gamesa has just had A bit of a PR issue with this whole thing.

It’s in, in corporate management, like if you have an, everybody’s going to go through either a product quality issue or some kind of. Business downturn, whatever. But it’s usually, okay, we can see this coming, we have a plan for dealing with it we know, what needs to ha and my point is that before you go out and say anything in public, you’ve dealt with everything that you can possibly deal with internally.

You can’t obviously withhold information, business critical information from shareholders, but you also want to be able to have your arms around what’s happening. And I think in their desire for transparency, and not wanting to be accused of hiding anything, they went forward with, publicly, with a lot of hey, we’ve got an issue here, but there was no road map for okay.

How do you deal with that issue? And then what’s the business strategy moving forward? They’ve just come out and you know been very transparent with the fact that they have an issue and we’re sitting here nine months later You know going on 10 or 11, and it’s you know, we’re still Scratching our heads trying to understand.

Okay, what exactly you know, when can you start selling again? When are you gonna start making money again? There’s it’s You know the things that they’ve said in the past are just unfortunately not convincing. And they’re talking about, oh, we’re going to be back in profitability by 2026.

Not if you’re not selling in 2024. So you best get on top of it. If you’re not already.

Joel Saxum: Yeah, that’s the interesting one, right? Chief executive officer, Christian brush come out. He says we’re going to stick to this prediction that we’re going to break even in 2026. With some of these fixes that we need to do the big spend probably being in 2025.

Which is, it’s such a general vague statement that it, that can’t give anybody a warm fuzzy, but how, however the early shares trading that rose 2. 8% and that adds to 20 percent gains so far this year after they slumped off about 30 percent in value. At the end of last year. So for the, I don’t know, the general investor that’s, they’re still feeling like it’s going to be okay is what it looks like, but I don’t know if from some looking at it as we do from the inside of the industry it’s still on thin ice.

Okay. So shifting gears. Now we’ve been talking about finance for a little bit. We’re going to talk back to O and M and what’s actually going on in the field. So up in Norway, a rotor fell off. Of a Nordic N 1 49 turbine. So this was in, I’m gonna say this wrong, of course, wind Park in Norway. They had an issue with one of the turbines back from the summer back in June.

And since then they corded off the area. They made sure nobody would go in there. They did everything safe there. But as a part of the repair process, they removed the gearbox. So they took some major components out of the inside of the nelle there. And it said, along with the company’s statement says this, along with other special circumstances surrounding the damage and repair work has led to an unusual risk that the rotor falling could, or the rotor falling, failing could fall off the turbine.

And on January 27th, the rotor became loose and fell off the turbine. So the interesting thing here for me is that they knew it could be an issue. They knew it could come off. There did they did some risk analysis and stuff on it, but they didn’t actually do anything about it to remove a major component.

Usually you have to have the gearbox or the gearbox. You have to have a crane there. You also have to have. Or a smaller crane system mobilized to site to even get this thing down. So there had to be something really weird going on with this turbine that they left it in a precarious position without actually just saying, hey, the crane’s here, let’s take the rotor off as well.

What do you heard anything else about this, Phil?

Philip Totaro: It’s a little bit of a strange one because it sounds like they, they needed to reinstall some tooling or other components that was gonna hold everything together, and mitigate some of that risk. But they just didn’t have some of that tooling available, is what they’re saying.

That’s unfortunate because, from that perspective, it’s going to be hard for them to make any kind of a claim, like an insurance claim or whatever, because this sounds like it was entirely the either on the OEM or EPC contractor to not follow a proper procedure, but it’s also a bit distressing because this product platform has had some Teething issues around the world like that.

They also had a rotor issue down in Australia the same model at the more like South wind farm recently. There’s also been a recent report of an issue in for a wind farm in Chile with the same same model, make and model of turbine. And it’s. Maybe this is one of those scenarios where it might be like a Nordex procedure that needs to be re evaluated.

Again, you never want to see a situation like this, but clearly something needs to be done if it’s, not just an isolated incident.

Joel Saxum: Yeah, the interesting, Nordex says They came out right away. This is an isolated incident. There’s no other risk to any other turbines on that wind farm or in the wider fleet.

No worries. And then the asset owner’s yeah, we’re going to do an RCA and figure this out. So there could be some more news that comes out of this rotor falling off of the turbine up in Norway.

Philip Totaro: And it’s also another reason why you need to have asset owners talking to each other and providing information exchange, which is obviously something that we’re trying to do with the.

The data licensing that we’re doing is trying to, shine a light on the fact that there are other asset owners that own the same product that you do, and potentially, they’re, they could also be experiencing issues or potentially operating their asset with the same make and model of product in a better way.

And so that’s the sort of thing that needs to happen within the industry is asset owners have to, and operators have to get. A little more comfortable kind of talking to each other and potentially sharing best practices and information so that things like this don’t reoccur. Because again, Nordex may come out and say, trying to reassure everybody, oh, it’s an isolated incident, but it hasn’t, when you do the root cause, I’m sure it’s going to be You know, something that was specifically different than the issue that they had in, in Australia, more like South or in Chile, as you mentioned, but it’s still, it seeing repeated issues on the same make and model of product.

is never really a good thing. So again, I think from a holistic standpoint, it might need to be a internal investigation into procedures that might need to occur here.

Joel Saxum: Yeah. Phil, we talk about this quite often. The OEMs don’t want to share that much data, which is, trade secrets and whatnot, but the operators can.

Some of them are covered under some contractual agreements to basically NDAs and those kinds of nasty little pieces of paper that can slow industries down. But there is a few working groups. I know there’s a Scandinavian working group that gets together and they talk about, with all the owners and they talk about things.

There is a blades one. I think that’s headed up by some people from Bladina and Burgett Junker that was with RWE. They talk about some blade issues to get together as a little conference. One of the ones I was at a few years ago, the last time they had it in person was the Sandia blade conference.

And there was quite a bit of. Good conversation there about best practices and what’s going on different kind of things. Not at the granular level, right? Not at the, hey, we have this platform with this blade and this and this. It was more like, hey, guys, let’s get together. What are some general things?

That Sandia is going to happen again this year. We saw that and they announced that down in Albuquerque. If you’re into, if you’re into blades and you want to know what’s going on in the. The US wind industry from an academic standpoint, but with a lot of great operators there and engineers, that’s a good conference to go to.

I think last year, last time they had it in person, there was probably 250 to 300 people there. And it was a couple of different tracks all about technical issues. So that one was good. We could see some of these things raised at that conference, but yes fully agree with you, Phil. It would be nice if we had yeah.

I don’t know what we would call it. The wind book, the Facebook of wind, and just everybody could be on there and share all the issues with certain things and maybe a nice forum there. I don’t know. And maybe it’s an IntelStor spinoff. Maybe we’re working on it. So that’s going to be it for the uptime wind energy podcast this week.

If you’re a frequent listener to the podcast, please take a moment and give us a five serving on your podcast platform and subscribe to our weekly newsletter, uptime tech news. And this was a big one. Don’t forget this. If you’re going to be at OMS ACP OMS in San Diego, IntelStor is putting on a perfect little event on Thursday night.

So go to their website or go to their LinkedIn, find the link for that, sign up. It’s going to be free to attend. A lot of good information there. Make sure you hit up that.

Siemens Gamesa, Vestas, Ørsted Updates: Finances, Fallen Rotors, and Offshore Wind Outlook

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Is Tesla Powerwall Worth It For Australian Houses In 2025?

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Australia, a country of vast open space and abundant sunlight, has firmly established itself as a global leader in rooftop solar adoption.  

According to recent data, the country has over 3.9 million rooftop systems installed, yielding a combined capacity of approximately 37.8 GW of PV. This remarkable achievement reflects the country’s strong commitment to a sustainable energy future. 

But what happens when the sun goes down or when the grid fails?  

Yes, that’s where home battery storage steps in, and no name resonates more loudly than Tesla Powerwall! 

With the release of the Powerwall 3 and evolving energy landscapes, many Australian homeowners are asking: Is a Tesla Powerwall still a worthwhile investment in 2025?  

If you’re an Australian looking for a home solar battery, Tesla Powerwall is arguably the most popular home battery on the energy market right now.  

So, here’s why Tesla Powerwall could be worth it for your Australian home!

But First, What Is Tesla Powerwall?

Back in 2015, Tesla ventured into the energy storage market with the Tesla Powerwall, a home battery system. This battery system is specially designed to store energy, mitigating the intermittency of renewable energy sources. 

Although Tesla was globally recognized for its electric vehicles, the launch of the storage battery, the Tesla Powerwall, marked another bold leap for the company.  

This home energy storage is a rechargeable lithium-ion battery that can keep your home illuminated 24/7 with reliable power and significantly reduce your electricity bills. 

Powerwall’s smart system can be tailored to your specific energy requirements. This battery can be charged from solar energy, ensuring that power is always available on demand. It essentially serves as a backup power source for nighttime or cloudy days.  

Following their initial release in 2015 in limited quantities, Tesla has continually expanded its energy lineup with larger-scale solutions.  

In 2025, Tesla’s lineup includes three Powerwall models: Powerwall 2, Powerwall+, and Powerwall 3. Each model offers 13.5 kWh of usable energy storage.  

In Australia, Powerwall+ and Powerwall 3 are designed for new solar and storage system installations, which involve integrating solar inverters for higher efficiency. At the same time, Powerwall 2 is often used for retrofitting existing solar systems. 

Now, they also offer different categories, such as the Powerpack, designed for commercial and industrial use, and the Megapack, engineered to support utility-scale grid operations, among others. 

How Does Powerwall Work? Find Out!

In general, the Tesla Powerwall is a rechargeable home battery system that stores energy for later use while providing essential security and financial benefits.  

It works seamlessly with solar panels or the electric grid to manage energy supply and demand in your home.   

It includes energy monitoring, metering, and smart controls, which the owner can customize and control via the Tesla app.  

The system then learns and adapts to your energy consumption slowly over time. It receives over-the-air updates to add new features and improve existing ones.  

How Does Powerwall Work

Here’s a step-by-step guide on how it works: 

Step 1:  Energy Collection 

  • With Solar Panels 

Your solar panels usually generate electricity during the day. From that, some of this energy powers your home, while the excess charges the Powerwall battery.

  • Without Solar 

If you don’t have solar panels, the Powerwall can charge using electricity from the grid when rates are low, for example, at night.

Step 2:  Energy Storage 

  • The Powerwall stores the unused electricity in its lithium-ion battery. 
  • This stored energy is saved for when you need it most, like during peak usage times, at night, or during a power outage.  

Step 3:  Energy Usage 

  • When solar production drops or the grid goes down, the Powerwall automatically kicks in, supplying your home with clean, stored renewable energy.

Step 4. Intelligent Management with the Tesla App 

  • The system learns your energy usage patterns and optimizes when to charge or discharge.
  • You can monitor and control everything through the Tesla app, giving you real-time insight into your energy use, storage levels, and solar generation.

The Australian Energy Rollercoaster: Why Batteries Are More Relevant Than Ever?

Undoubtedly, Tesla Powerwall 3 is one of the most exciting innovations to hit the market in recent years. Tesla’s next-gen home battery is designed to supercharge solar systems and dramatically reduce the reliance on the grid.  

For Australian homeowners, it’s a total game-changer, offering a smarter way to store solar energy and power homes more efficiently than ever before. 

Curious about the other benefits of the Tesla Powerwall 3? In the following part, we’ve rounded them all up for you: 

  • Powerwall Batteries Maximize Self-Consumption  

Using your own solar power, especially during the expensive evening peak, saves you significantly more than exporting it to the grid.  

The Powerwall stores your excess daytime solar to power your home at night with free, clean energy. 

  • Battery Storage Reduced Electricity Bills 

Adding a Powerwall battery to your solar panel can drastically reduce your reliance on grid electricity during peak hours, leading to substantial savings on your energy bills.  

Some reports suggest adding solar batteries has reduced electricity bills by over 70% in many Aussie homes in the past few years. 

  • Ensure Energy Independence & Security 

The Powerwall provides seamless backup power for essential appliances, ensuring your lights stay on, your fridge stays cold, and your devices stay charged during any unexpected blackouts. 

  • Smart Energy Management 

The Tesla app provides intuitive monitoring and control over your energy usage. You can track your solar generation, battery charge, and household consumption in real time. 

This allows you to optimize your energy habits and maximize savings. 

  • Virtual Power Plant (VPP) Participation 

Through VPP, you can earn money by letting your battery support the grid during high-demand hours.  

This will benefit your wallet and contribute to a more stable and renewable energy network for everyone. 

  • Environmental Impact 

Batteries can reduce your reliance on fossil fuel-generated electricity, significantly lower your carbon footprint, and contribute to a cleaner, more sustainable future for Australia. 

  • Increased Home Value and Building Aesthetics 

Homes with solar and battery systems are increasingly attractive to buyers. They often command a premium due to lower running costs and increased energy resilience.

Tesla Powerwall 2 vs Powerwall+ vs Powerwall 3: The Evolution of Home Energy

Tesla’s Powerwall series has become a symbol of energy independence. From the Powerwall 2 to the all-in-one Powerwall+, and now the game-changing Powerwall 3, Tesla continues to push the boundaries of home energy storage. 

Let’s break down what makes each Powerwall unique and why Powerwall 3 is the most powerful one yet. 

Tesla Powerwall 2: The Energy Game-Changer

Launched in 2016, the Powerwall 2 was a massive leap in energy storage for homeowners.  

It is ideal for those with existing solar systems or those seeking basic backup and energy optimization. 

Key Highlights: 

  • 13.5 kWh usable capacity, which is sufficient to power an average home overnight.
  • 5 kW continuous power output. 
  • Backup power during outages.
  • Sleek wall-mounted design.
  • App-controlled smart energy management. 

Powerwall+: Energy Storage Meets Solar Intelligence

The Powerwall+ is built on the foundation of Powerwall 2 and adds a major upgrade: an integrated solar inverter. 

Why It’s Smarter: 

  • Same 13.5 kWh battery capacity.
  • Higher peak power output (up to 7.6 kW) 
  • Integrated solar inverter with 4 MPPTs (Maximum Power Point Trackers)
  • Optimized for real-time solar generation and storage.

Powerwall 3

Powerwall 3: The Energy Upgrade Your Home’s Been Waiting For

Announced in late 2023 and rolling out through 2024, Powerwall 3 is Tesla’s most powerful home battery yet. It’s designed to meet modern energy needs, including higher loads, faster charging, and seamless integration with large-scale solar systems. 

What’s New: 

  • 11.5 kW of continuous power, which is more than double Powerwall 2 
  • Still offers 13.5 kWh capacity.
  • Integrated solar inverter with expanded capabilities
  • Designed for quicker installation and lower labor cost
  • Ideal for large homes, EV charging, or heavy appliance use 

So, with all these incredible upgrades, making it smarter, more efficient, and future-ready, don’t you think Tesla Powerwall is worth it?  

What else could you ask for? We’re pretty sure this is the battery your home’s been waiting for! 

The Actual Cost of a Tesla Powerwall: Is it Worth It?

Let’s not sugarcoat it, a Tesla Powerwall is a significant investment. As of mid-2025, the Powerwall 3 unit itself costs approximately AUD 11,900, with the essential Backup Gateway 2 adding $1,700. This brings the total hardware cost to approximately $13,600 AUD. 

Installation costs can range from $1,000 to $ 2,500 or more, depending on your location, system complexity, and the installer.  

This puts the total installed cost of a single Powerwall 3 in the ballpark of $14,600 to $16,000 AUD. 

While this might seem steep, it’s crucial to factor in the various incentives and potential savings.

The Australian Government’s Rebates and Incentives in 2025

Good news for Australian homeowners! 2025 is a sweet spot for solar battery rebates, with a significant federal program coming into play: 

  • Federal Cheaper Home Batteries Program (Starts July 1, 2025) 

The Australian Government has announced an upfront discount of approximately 30% on the cost of installing eligible small-scale battery systems (between 5 kWh and 50 kWh).  

For a 13.5 kWh Tesla Powerwall 3, this could translate to a rebate of around $4,725. The discount is based on usable capacity and will gradually decrease until 2030, making 2025 the optimal time to jump in.  

The discount is applied upfront by accredited installers, making it easy for consumers. 

  • State-Based Incentives 

While the NSW Peak Demand Reduction Scheme (PDRS) battery rebate ends on June 30, 2025, it will be replaced by an expanded Virtual Power Plants (VPP) incentive from July 1, 2025, offering a single upfront payment of up to $1,500.  

Other states like Victoria (interest-free battery loan up to $8,800), ACT ($15,000 interest-free loan), and Western Australia (up to $7,500 rebate and loans) continue to offer their own incentives.  

Altogether, these rebates dramatically lower battery costs, often by 30–50%, making the Powerwall 3 far more accessible.  

Top 5 Tesla Powerwall Alternatives Available in Australia

The Australian battery storage market is vibrant and competitive. While Tesla is a dominant player, several other reputable brands also offer excellent alternatives. 

Looking for something beyond Tesla Powerwall?  

Here we’ve listed some of the best battery brands in Australia in 2025: 

  1. LG Energy Solution RESU: Known for their reliability and various capacity options. 
  2. BYD Battery-Box: A popular choice for its modularity and competitive pricing. 
  3. Sungrow: Offers a range of battery solutions, often paired with their inverters. 
  4. Enphase Encharge: A good option for microinverter-based solar systems, offering modularity and resilience. 
  5. Alpha ESS: Alpha ESS battery provides integrated solar and battery solutions. 

Parting Thoughts

Tesla’s Powerwall ecosystem offers energy resilience, grid independence, and smart control. With the release of Powerwall 3, Tesla is responding to the growing demand for higher capacity, smarter tech, and easier installs. 

In Australia, the home battery market is gaining traction, with data showing that the majority of homeowners are opting for the Tesla Powerwall.  

So, whether you’re going solar for the first time or upgrading your energy system, the Powerwall lineup has top-notch options tailored for your home. 

By the end of 2021, battery installations had increased by 400%, and the majority chose the Tesla Powerwall. With our affordable solar packages, you can make your dream of owning a Tesla Powerwall a reality.   

Still unsure?  

Contact a certified installer, such as Cyanergy, to explore your options tailored to your home, location, and future needs. Get a free quote today and learn more about the Tesla Powerwall battery price, rebate availability, and installation details.

Your Solution Is Just a Click Away

The post Is Tesla Powerwall Worth It For Australian Houses In 2025? appeared first on Cyanergy.

Is Tesla Powerwall Worth It For Australian Houses In 2025?

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IWTG Consulting Addresses Turbine Failures

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Weather Guard Lightning Tech

IWTG Consulting Addresses Turbine Failures

Jon Zalar, founder of IWTG Consulting, discusses the challenges of wind turbine maintenance, emphasizing the rise in turbine failures and the importance of root cause analysis (RCA). Proactive maintenance, proper documentation, and expert consultation will help to mitigate issues and ensure turbine efficiency.

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 FacebookYouTubeTwitterLinkedin 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!

Welcome to Uptime Spotlight, shining light on Wind. Energy’s brightest innovators. This is the Progress Powering tomorrow.

Allen Hall 2025: Jon, welcome to the program.

Jonathan Zalar: Thanks for having me,

Allen Hall 2025: Jon. Let’s start with the reality facing wind farmer operators today. What’s the core problem when it comes to turbine failures?

Jonathan Zalar: There’s been a larger number than they probably experienced like five years ago. I think, um, you know, the volume of turbines out there and some of the bigger issues that, you know, people are seeing in the last two to three years has made owning a wind farm a little more challenging than before.

Um, you know, between blade issues, bolted joint issues, shoes, and. Overall, like o operations, right? It’s been tougher to keep these turbines up and running, you know, manpower’s an issue, getting people out there to go fix stuff. It’s, [00:01:00] it’s been tough for a lot of people I’ve talked to.

Joel Saxum: Do you think this is a, a partial result of like, um, okay, so what we’re, you know, on the podcast in the last few years, we’ve always been talking about, oh, there’s all kinds of models coming out and there’s this, this manufacturer can put out this many different variations and all these things, and now.

Now we’re getting to the age where that family, that group of turbines that, I guess it’s kind, I’m looking at it like a class, right? That class of, that, those years of turbines are now getting to the stage where they’re out of warranty and they’re coming into, some people are taking, you know, ISPs taking, um, maintenance of them or an owner operator taking maintenance over from the OEM.

And all of a sudden now there’s these issues popping up and different things that we’re, we’re kind of in this. Um, like a swamp of problems with a lot of different models. So, uh, yeah, like you said, we’ve we’re, we talked a little bit off air here about RCAs and how to fix things and looking at serial defects and stuff, but it’s just like, it seems like every other week [00:02:00] someone calls Alan Ryan’s like, Hey, have you heard about this thing with this model?

And it’s like, man,

Jonathan Zalar: another one. I think it’s a combination of two things. One. Like I talked about the last time we had podcasts, there was a, you know, a pretty big push to increase rotor size, come out with new models for, for every, for all the os, right? They’re competing against each other. Coming out with a new model every 18 months.

And you can ask Phil, but I believe mostly the OEMs are sold out. If you go back five, six years, where. A huge expansion in the amount of wind turbines that have been placed. Right. So I think you combine those cheap factors and now, yeah, the owners have a lot on their plate, a lot more than they’re

Allen Hall 2025: probably used to.

And my question all is this, the complexity of the turbines. So every new model that comes out, what I’m seeing is more instrumentation, more sensors, more stuff, more variability, even in where the components originate from.

Jonathan Zalar: Right? Yeah. [00:03:00] I mean, to increase, to be able to meet that increased demand the OEMs had to get, you know, a lot of different suppliers for bearings for, you know, maybe two or three different places to make blades, right?

Um, and you’re right about the complexity, right? So like these rowers are getting bigger. They were trying to keep as many components the same. So you need better sensing, better controls to, you know, keep those loads where they work.

Allen Hall 2025: And a lot of times, uh, when operators have problems, they don’t actually realize.

What to do or realize that maybe there’s a serial defect and how to address it and how to suss that out. Now the, the big question is, is like what’s at stake if the operators don’t implement some sort of proper root cause analysis? Uh, what does that sort of downward spiral look like? Because we have seen operators that do that, that, that don’t try to identify key issues with their turbines.

I

Jonathan Zalar: mean, at the end of the day, it costs money, right? So if the quicker you figure out an [00:04:00] issue and if it’s a solution for an issue, the quicker you’re gonna solve that problem for your site or your fleet. Um. Also like making sure you’re communicating with the OEM about your failures so that they can add them to their RCA if they’re working on one, for example.

The more data they have, it’s gonna help them come up with a more effective solution.

Joel Saxum: I think you’re, you’ve gotta, how to put this? You have to have a specific engineering mindset. So of course we’re dealing with engineers all day long. We’re all engineers. We enjoy the engineering mindset. So it’s easy for us to quantify ROI and value add from an RCA, right?

So, hey, we’re gonna bring in an expert, or we’re gonna bring in a consultant, or whether it’s a, you know, a big one, A DNV, a UL type, or it’s a Jon Zalar, it’s gonna cost us a little bit of money, right? It’s gonna cost us. 5, 10, 20, 30 grand, what, whatever that is. But to us, that ROI is easy to quantify, oh, we had [00:05:00] this issue on this turbine.

We’re gonna spend 20 grand figuring out why, what, how, and how we fix it in the future. Well now we can avoid that blade failure. Next time we can avoid, you know, a de deductible on an insurance case, $250,000. So boom, we, if we save one of those, we paid for the whole RCA. It’s easy for us to do that in that engineering mindset, but to get, sometimes to get.

You know, an asset manager who may not have that engineering mindset, they’re just looking at, um, dollars and cents. They’re like, yeah, do we wanna spend this money? And, and I, I think that that’s a, uh, uh, a mindset, a, an action, an operation that, you know, us as evangelists for engineering in the industry need to help because we can help it in a large scale, right?

Like if we, if we solve these problems through RCAs. Then we can avoid ’em in the future and it’s better LCOE for the entire fleet. That’s the goal,

Jonathan Zalar: right? Like even if you identify an issue and you have the ability to figure out how many [00:06:00] turbines are affected and like we use a Blade Blade issue, right? If you only catch the CAT five, that’s a much more expensive repair than a cat two or three.

So if you work with somebody to identify, hey, this lat or you know, this list of turbines have a better chance of having this problem, let’s inspect it a little more, for example. Or let’s proactively add some strength in one area that we know we’re seeing issues that could save a lot of money in the long run.

’cause blade repairs are expensive. They take time, weather out. It just adds up.

Allen Hall 2025: And what I see when Joel and I have been around a lot of, uh, wind turbines in the Midwest, is that the asset managers. Get a lot of complaints from the neighbors and the landowners. So if they have a blade break or they have some sort of bearing that’s going bad, that’s making a lot of noise.

It’s a constant set of phone calls from the surrounding landowners about this problem. So even in the simple things. That can be [00:07:00] fixed, turn into big problems because of all the associated people that are around it. I mean, Joel, you’ve, you’ve seen some of these cases where, like a bearing’s squeaking, okay.

And the neighbor complains, or a blade breaks and the, and the owner calls up and say, Hey, why is this blade in my front yard? Which has happened? And those are real life situations that, that. You know, re requires somebody with knowledge to catch them before they turn into that neighborhood problem. Yeah.

That’s

Joel Saxum: the intrinsic side of, of the return on investment, right? Like, you can’t measure that, but it’s valuable. And, and I, and we get, this concept comes up a lot to us because we’ve been doing a lot of work in Australia lately, and Australia has a different approach to their neighbors and how they work within things.

And it’s very, very, very hands-on. Where in the states sometimes you see like, oh, well, they’re a non-participating landowner, so we just kinda, you know, move on. And then you see the Facebook posts that are like, these turbines take a thousand gallons of [00:08:00] oil a year and they never run. You know? And if we can, as an industry, if we can avoid those things by getting on top of stuff with RCA, we can, we can get ahead of the game, right?

We can change the perception of, of renewables as we move forward. Um, which is, I mean, it’s a difficult battle, but that’s, as engineers, we can, we can help that fight. So I think that this is an important thing. That’s why we’re talking to you, Joe.

Jonathan Zalar: Yeah, I agree. I mean the, the video of the guy who was asking why it wasn’t turning, ’cause there was no wind.

I’ll never forget that one.

Allen Hall 2025: So how do we break this cycle of reactive maintenance and repeated failures? What should we be doing?

Jonathan Zalar: Continuing that relationship with the OEM, making sure you’re having those monthly quarterly calls, sharing information back to them and making sure that you’re getting the updated information from them.

Because, you know, all the major OEMs have like information letters they provide when there’s an a known issue and they give recommendations of what to do to fix it. And just making sure that you’re plugged in, especially the smaller owners that you’re plugged into the oem, just make sure you get that [00:09:00] information.

You know, some could be a parameter setting or a increase inspection or, or a safety concern as well. Just keeping that relationship I think is important.

Joel Saxum: So, Jon, so continue on that, that thread at what, at what point does. Because not everybody is able to keep that relationship really good. And sometimes OEMs don’t wanna share a little bit, at what point does an operator say, I’m taking on an RCA myself.

I’m going to get a consultant in here. Or we’re gonna take it on in our internal team. what, how do you make that call?

Jonathan Zalar: It’s looking at their relationship and if it’s not there, and that does happen. There’s breakups in the industry, if you will, and. You see three or four of the same failures at a, 50 wind turbine park.

it should be a little bit of a yellow flag. I wouldn’t say red yet, but one turbine fell over. That’s a red flag, and that’s when if you’re not getting what you need and you don’t know what to do about it, that’s when you call somebody else out because. [00:10:00] The next one’s gonna be just as expensive, and there could have been a way to make it either cheaper or not happen.

Allen Hall 2025: let’s, get down to specifics now, because I think a lot of problems in the United States are related to bolts at the minute, and I, this may be a worldwide problem, that there seems to be blade bolts and pitch bearing bolts that are. Have cracked or are failing in some unique ways. And I’ve seen more recently where operators are just replacing them.

Like they, they don’t think about it in a larger context of maybe there’s a problem here. Maybe I need to be flagging these things. And they don’t bring in an expert like you, Jon, to come in and do an RCA To suss this out, you want, can you give us just a little bit of background on what’s happening on the, blade bolt and pitch bearing bolt problem?

Jonathan Zalar: It is multiple OEMs are having. I think three or four different failure modes that I’ve heard so far between root inserts, just the bullet joint itself, and then potentially just some initial torquing issues. Um, I know from my experience there have [00:11:00] been update updates to the bold, the bolt torque.

Specifications. And back to my comment about the relationships, like if you’re not getting that information, then you might not know. You should have went back and retort all these bolts and now you have a couple fail. Fail. Right? And then also what you do about it, when you have one that comes out, do you replace just the one or do you replace four to the left and four to the right?

So d different solutions I have seen from different OEMs about what to do when you do have one particular bolt fail. Um, you know, there’s definitely some potential supplier concerns. ’cause like I said, there’s been so many turbines with so many bolts, like you’re gonna have some manufacturing issues. You can’t get over that With the volume of bolts that are out there.

Joel Saxum: Do you think the technology innovations in bolting and tensioning tools right now are gonna help or hinder. Bolting problem.

Jonathan Zalar: I think they’re gonna help. Um, you know, [00:12:00]torquing, big bolts have been a problem in multiple industries. Even when I worked in locomotives, you know, getting high torque to come out with the right size tool to be able to get in there, to go, to go put the locomotive back on the frame.

Right. It is a very hard job. And you had mean you looking at 92 bolts on one axis, then you got tower bolts. I mean, it’s a very, very boring job, I’m assuming for the people that have to do that. All the time and having tools that make it easier, have a, have a less chance of not hitting that torque value, setting something wrong, not putting the tool in properly at an angle, for example.

I, I think the more, at least what I’ve been seeing recently, the more money and effort people are putting into, like making bolted joints. Is gonna be worth it.

Joel Saxum: Well, and I think this is why, like this is the importance of an RCA, right? Because at that level of, say, new construction or repowers, people are just pointing fingers like, oh, the technicians did this wrong, or whatever, blah, blah, blah, blah.

Or you get an RCA specialist to come in and can do, you know, the [00:13:00]eight eight DRCA or if they throw an RCA and figure this thing out properly and be able to point to, well, actually there’s a. A metallurgical defect in these bolts and you know, it’s a supplier issue or, or maybe it does the RC may point, Hey, these guys were at the bar the night before they torked this one or something.

You

Jonathan Zalar: know? Or, or could be like crew a just happens to not pay attention or, or had or had the wrong information. They had the old bolted joint, this tribal knowledge.

Joel Saxum: Exactly. And speaking about the problem there, like if we’re down the line, say now out of warranty, and we’re looking at a bolted connection issue.

It may point to once you’ve stretched those bolts a certain amount, if you’re re torquing or changing torque specs or something along the way that’s done, like that’s cash, like that doesn’t, it doesn’t work like that called yield.

Jonathan Zalar: Yes.

Allen Hall 2025: Well, especially composites though, when you start talking about these bushings that are in the blades.

You pull them, they’re, they don’t recover. They just get damaged. It’s not like some metal and it can stretch. You don’t really stretch [00:14:00] composites. You break composites.

Jonathan Zalar: Right. Once it loose is once it’s loose, it is adherence, it’s done right. You have to go do something, get it back. And I know there’s some technologies out there trying to fix some of these inserts, but yeah, like once you do that damage.

It doesn’t heal itself.

Allen Hall 2025: Right. And I think there’s a lot of misunderstanding about that right now in the field because it, they’re not talking to engineers. They feel like, well, we’ll just cinch it back up and it’ll be okay. No, that joint is done. It’s done. You need to have somebody come in and look at it and give you some really good advice.

Joel Saxum: So to get to that level, Jon, you need to go through an investigation process. Can you give us some of the like, tips and tricks for the investigation process that like, that you know of, that you, that have helped you in the past? Data quality is very important,

Jonathan Zalar: like making sure, you know, like what turbine, which bolts, how many bolts, when did it happen, when were they last touched?

Like documentation is not always the best in the field. There’s a lot of handwritten stuff I [00:15:00] know that, you know. Companies are getting much better with electronic documentation, but that didn’t always exist in the beginning, like four or five years ago, surprisingly. Um, and then also like having the expectations where an RCA doesn’t take a month.

If someone, if someone calls you up and says, I need an RCA in a month, they don’t want RCA, that’s it. They’re not that fast. You really need to look at what’s going on, collect the data, put a hypothesis together, and. Validate or invalidate it and repeat if needed. And then you have corrective action. And that takes time.

That takes a commitment from the customer as well as you know, whoever they’re working with.

Allen Hall 2025: And that corrective action is the real key. But it’s hard to get to the corrective action if you don’t know what the root cause is. I see a lot of corrective actioning happening out in the field. Like they assume they know what’s happened, but not the details.

And you’re right, Jon, it’s gonna take more than a couple of days. To suss this out because there’s too [00:16:00] many variables and there’s not a lot of information, particularly when you show up on site. A lot of operators haven’t kept the real detailed records that you would need to be able to point it in in an afternoon.

Like, yes, this is it. Right?

Jonathan Zalar: Unless it’s a known issue that you’re not aware of and somebody else tells you, oh, yeah. G has his tail go do this, whatever this is. Right.

Allen Hall 2025: And how does that play out between the different OEMs at the minute? Are they basically providing the same level of information about, uh, known problems?

I have very little experience with like, um, I don’t know. Intercon for example, I haven’t seen a lot of Intercon service bulletins. I’ve seen Seaga Mesas and GEs Iveta. They’re pretty on top of it, but there’s other turbines that are out there, Solan. Well, how does that work?

Jonathan Zalar: That’s a very good question.

’cause I’m not seeing very many from Intercon or Solan either. And I believe they have some bigger companies that are responsible for them now. Um, [00:17:00] it’d be interesting to see. What kind of level that a turbine, that old without, you know, their OEM’s gone. Right. Someone else bought ’em out at some point.

Allen Hall 2025: Well, it’s like the Mitsubishi 1000 A’s, which is a really good example because a lot of the Mitsubishi 1000 A’s, and there are a number of them still in the states are, are being repowered at the minute.

So they’re gonna have another 20 years of lifetime. But I, you know, Mitsubishi probably doesn’t really provide a lot of service on those. What do you do? If you have an issue on a Mitsubishi or an old Suland machine or even an old GAA machine, where are you going to get help? I

Jonathan Zalar: mean, you, you really need to go to like an independent engineer that has that kind of experience, you know, hopefully with that particular turbine model.

But if not, you know, people who do follow known RCA processes, we will be able to like work through issues like that.

Allen Hall 2025: Is there a network of RCA people in the industry? I know you. Because you’re the [00:18:00] best. So, I mean, I’m talking to you all the time, Jon. I’ve seen this problem of the turbine tell me what’s going on.

But is there a, a general network of people that are just out there focused on solving these problems?

Jonathan Zalar: I don’t think the market’s huge in that right now. I mean, yes, there’s some independent people like myself, and then you have your DNB Leidos, those type of companies that that will do RCAs. But I don’t think they have dedicated RCA teams.

I think. The OEMs are the ones with the dedicated OEMs and then a handful of people like me.

Allen Hall 2025: So let’s, let’s walk through that for a minute, because one of the questions that pops up when someone’s trying to solve a problem is like, why not bring in a big organization like the one you just mentioned to, to do the RCA?

Like we, we, we’ve hired, uh, the three letter acronym to come in and do the RCR, the two letter acronym to come in and do the RCA. There’s a downside to that. I think I, I’m not always sure that the, the competency is there based [00:19:00] upon the, just what I see for the level of person that’s been assigned to that.

When they have so many RCAs and requests coming into the door, can they. Manage it at a level that you as the customer would be happy with.

Jonathan Zalar: I don’t deal with it too much, but you’re right, it, it will depend on the person you get Right. When you’re using one of the bigger one. Right. And you know, I’m sure some customers have the opposite, like, oh, I got the best guide or girl I could get for this.

Right.

Allen Hall 2025: Have you seen the varying in quality there, Joel? Like if you just call out the big name and pick up the phone and call the name. You don’t always know what you’re getting

Joel Saxum: there. We know, we know some really good people in the industry that has specific problems, but the trouble is, is scaling engineering expertise is tough.

Right. So like if you have a, you have a Jon Zalar on the phone, you get an awesome engineer that knows how to do RCAs, but you only get Jon Zalar, right? You, you, you can’t expand that. A million things like Jon Zalar can’t take out 58 RCAs this week because he’s Jon Zalar. Whereas, whereas I think that some of the [00:20:00] bigger houses, you get the strength of having a, uh, the larger team behind some of them where they can kind of spread some work out.

Or you may have an expert in fracture mechanics that he can look at this and somewhat so you have that with the larger teams, which I think is an advantage and you get some varying opinions in the room and you can really sort down to certain things. But at the end of the day it, it, it’s exactly that.

It’s an engineering expertise shortage

Jonathan Zalar: off. You know, it’s also nice when they have a good network. Of people that they’ve worked with in the past to bounce ideas off of. Because like if you’re the only one doing RCA all on your own, you’re gonna second guess yourself a lot. But like having somebody who does have.

A lot of contacts and colleagues in the industry. I think that’s very helpful.

Allen Hall 2025: Well, a new avenue for root cause analysis is looking at the service providers. I’ve noticed that, uh, you know, it’s one thing if a product comes to an OEM, you, you kind of know what you’re dealing with there. But when a company’s out there, uh, independent service provider or maybe some out there on a contract is [00:21:00] doing work on your turbine.

Now RCAs are looking into those service providers. Jon, are you involved with some of those discussions?

Jonathan Zalar: It’s, you know, not just the service provider, it’s even like who’s doing the work. Are they actually doing what they say they’re doing? Um, are they following the OEMs maintenance schedule correctly? Um, you know, especially some of the owners that farm out the whole operations to somebody else.

Double checking their work, I think is important just to make sure, I mean, you, even if you have total control and people, but just having a second set of eyes doing some quality checks. I, I, I don’t think that enough of that’s being done in the industry at this point. I think there’s opportunity to get

Joel Saxum: better.

The bird dog concept, right? The bird like oil and gas is bird dogs everywhere in the onshore, offshore. Anything you do, they gotta, they got a client rep who is rolling around making [00:22:00] sure things are done right. And I think we need that in wind too. And it’s not any different if you look at the same thing.

Remote operations people are like, oh, wind farms are all over the place. Like, have you looked at any other In industry, it’s the same thing.

Jonathan Zalar: It it, it’s harder. There’s more of them and they don’t move, like, you know, like a locomotive or automobile, right. Where they come to the shop and you can overlook, see what somebody did.

But yeah, like spending that money and effort on. Quality, I think could go a long way. And one of the ways would be the bird dog method that you suggested.

Allen Hall 2025: Yeah, I do think some of the issues we’re seeing in the field are related to particular groups that have touched the turbines, and maybe they just don’t have the latest and greatest information from the OE em, or maybe they’re just winging it, but either case, uh, the sampling there needs to happen and it really gets down to knowing what’s happening with your turbine.

And then when it doesn’t seem right. Getting an expert on site to take a look and make sure that your turbine is operating like you think it should and [00:23:00]it should be producing like it should, because if anything, we know right now production is key. We need those turbines up and running. Jon, you know, a lot of people call us and ask us, how do I get ahold of Za LR?

Do you have an email for Jon? How do people get ahold of you? I send ’em to your website, i wtg consulting.com. But they, you know, they want your mobile number, which I try to avoid giving them, but how do they, how do they reach you?

Jonathan Zalar: Um, the website, it’s got a form there. Um, they can also email me at Jay zr@iwtgconsulting.com.

Allen Hall 2025: Well, you can see Jon on LinkedIn. It has a lot of good posts on LinkedIn and you’ll see him. Around the country and the world at different symposiums and discussions about wind turbine operations. Uh, and you can always feel free to talk to Jon Jon’s easy to talk to. So Jon, so thank you so much for being on the podcast.

We love having you. Thanks for having me, guys. I appreciate it. It was [00:24:00] fun.

https://weatherguardwind.com/iwtg-consulting-failures/

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The Lightning Diverter Problem with GE Vernova Blades

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Weather Guard Lightning Tech

The Lightning Diverter Problem with GE Vernova Blades

A design that causes massive problems

As wind turbine operators continue to expand their fleets worldwide with larger turbines, bigger generators, and longer blades, the risk of significant lightning damage continues to plague the industry. Lightning is now the leading cause of unplanned turbine downtime for many operators. In years past, OEM warranties or insurance would cover the costs of repairs and business interruption. Those days are gone. OEMs have eliminated lightning damage from warranties and insurance companies are dramatically raising rates, or eliminating coverage, for lightning damage. That leaves operators exposed to millions in repair bills every year.

The SafeReceptor ILPS System

The basic lightning protection systems for LM Wind Power blades has been two small, coin-sized receptors placed on either side of the blade tip. Designated as the SafeReceptor ILPS, the receptors are connected to an insulated metal cable that runs through the center of the blade which connects to the hub, nacelle, tower and eventually earth. Certified to IEC61400-24, the SafeReceptor ILPS has been used on most onshore LM Wind Power blades since 2011.

LM Wind Power would, occasionally, place a special, additional lightning protection feature onto their blades. Patented in 2005, this lightning add-on contained a line of stainless steel cross-shaped buttons in a soft, gray-colored sealant which formed a segmented lightning diverter. As lightning approached a blade, the LM segmented lightning diverter helped guide the lightning to the receptor, lowering the chance of lightning damage to the blade.

LM Wind Power, and eventually TPI Composites, used the LM Wind Power segmented lightning diverter. Most installations of the LM segmented lightning diverter placed the device behind the receptor – using the receptor to block rain and airflow impact. The reason? If the LM Wind Power diverter was directly exposed to the wind and rain it would eventually degrade.

Remarkably, the LM diverter strip was used sparingly, or not at all, on the LM/TPI 56.9m and 62.2m blades. As it turns out, the 56.9m / 62.2m are unusually vulnerable to lightning damage. In a WGLT study of over 900 GE Vernova onshore turbines in Texas and Oklahoma with blades exceeding 50m, the rate of lightning damage was approximately 1 in 5 strikes. The industry standard for lightning damage is roughly 1 in 50 strikes per the IEC standard. That results highlight a gigantic risk for wind turbine operators.

Presumably in response to these high damage rates, GE Vernova has introduced LPS “improvements” to the 56.9m and 62.2m blades. Two additional receptors have been added to the blade approximately 3m from the blade tip. Also, LM Wind Power diverter strips have been added to every receptor; with short pieces behind the tip receptors plus long pieces behind and in front of the two receptors down the blade.

The Lightning Diverter Problem with GE Vernova Blades
Latest GE Vernova 62.2m Blade Design

This is a risky decision by the blade designers at GE Vernova. Most lightning strikes occur when blades are pointed upwards towards the sky – and segmented lightning diverters provide maximum protection when they are also pointed towards the sky. GE Vernova placed the LM Wind Power diverters parallel with the airflow over the blade – perpendicular to the sky – which dramatically lowers their lightning protection ability.

The Lightning Diverter Problem with GE Vernova Blades
LM Wind Power Lightning Diverter Installation

Why are the LM Wind Power diverters not oriented upwards towards the storm clouds? Our research indicates that exposing the broad side of the diverter to rain erosion causes the part to fail.

Several years ago, Weather Guard Lightning Tech developed an accelerated rain erosion test rig to mimic rain erosion that appears on aircraft nose radomes and wind turbine blade tips. This test sprays water droplets onto test samples at 135 m/s (300 mph) and has yielded accurate predictions for lifetimes. WGLT examined the durability of the LM Wind Power diverters in our accelerated rain erosion test rig. The results were astonishing. The LM Wind Power diverter failed in under 1 minute for every orientation.

The Lightning Diverter Problem with GE Vernova Blades

And here are the images of the test articles after rain erosion testing.

The Lightning Diverter Problem with GE Vernova Blades

Sample 2 Post-Test 90 Degrees to Face of Diverter

The Lightning Diverter Problem with GE Vernova Blades

Sample 5 Post-Test 0 Degrees to Side

The Lightning Diverter Problem with GE Vernova Blades

Sample 6 Post-Test 0 Degrees to Leading Edge

Now, what does this mean for the lightning protection for your GE Vernova wind turbine blades with LM Wind Power diverters? You need to monitor the diverters for damage and peeling off the blade. Missing metal segments from a diverter or sections of diverter that have separated from the blade need to repaired or replaced.

The Lightning Diverter Problem with GE Vernova Blades

What’s the risk? Your blades are susceptible to significant lightning damage which could cost you $$$.

For more information about StrikeTape lightning protection technology and installation services, contact Weather Guard Wind at 1.413.217.1139 or info@wglightning.com.

About Weather Guard Wind: Weather Guard Wind specializes in advanced lightning protection solutions for wind energy applications, with installations protecting turbines worldwide in the most challenging lightning environments.

https://weatherguardwind.com/the-lightning-diverter-problem-with-ge-vernova-blades/

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