Published

3 months ago

December 2, 2025

Alice Rush

Weather Guard Lightning Tech

Statkraft Sells Offshore Wind, Torsional Blade Testing

Allen and Yolanda discuss Statkraft’s workforce cuts and sale of its Swedish offshore wind projects. They also cover ORE Catapult’s partnership with Bladena to conduct torsional testing on an 88-meter blade, and the upcoming Wind Energy O&M Australia conference.

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!

You are listening to the Uptime Wind Energy Podcast brought to you by build turbines.com. Learn, train, and be a part of the Clean Energy Revolution. Visit build turbines.com today. Now here’s your hosts, Alan Hall, Joel Saxon, Phil Totaro, and Rosemary Barnes.

Allen Hall: Welcome to the Uptime Wind Energy Podcast. I’m your host, Allen Hall in the Queen city of Charlotte, North Carolina.

I have Yolanda Padron in of all places, Austin, Texas. We’re together to talk to this week’s news and there’s a lot going on, but before we do, I want to highlight that Joel Saxon and I will be in Edinburgh, Scotland for the re Catapult UK offshore supply chain spotlight. That’s on December 11th, which is a Thursday.

We’re gonna attend that event. We’re excited to meet with everybody. Over in the UK and in Scotland. Um, a lot of people that we know and have been on the podcast over a number of years [00:01:00] are gonna be at that event. If you’re interested in attending the OE Catapult UK Offshore Supply Chain spotlight, just Google it.

It’s really inexpensive to attend, and I hope to see most of you there, Yolanda. There’s some big news over in Scandinavia today, uh, as, as we’re reading these stories, uh, the Norwegian State owned Utility Stack Craft, and it’s also one of Europe’s largest renewable energy companies. As, uh, as we know, I’ve been spending a lot of money in new markets and new technologies.

Uh, they are in electric vehicle charging biofuels and some offshore wind development. Off the eastern coast of Sweden. So between Finland and Sweden, they’re also involved in district heating. So Stack Craft’s a really large company with a broad scope, uh, but they’re running into a little bit of financial difficulty.

And this past July, they announced some [00:02:00] workforce reductions, and those are starting to kick in. They have 168 fewer employees, uh, by the end of this third quarter. 330 more expected to leave by the end of the year when all the dive are complete. This is the worrisome part. Roughly 1000 people will longer work for the company.

Now, as part of the restructuring of Stack Craft, they are going to or have sold their offshore portfolio to Zephyr Renewable. Which is another Norwegian company. So Stack Craft is the Norwegian state owned renewable energy company. Zephyr is an independent company, far as I can tell my recollection that’s the case.

So they agreed to acquire the bot, the uh, offshore Sigma and Lambda North projects, which makes Zephyr the largest offshore wind developer. Sweden, not Norway, [00:03:00] in Sweden. Obviously there’s some regulatory approvals that need to happen to make this go, but it does seem like Norway still is heavily involved in Sweden.

Yolanda, with all the movement in offshore wind, we’re seeing big state owned companies. Pulling themselves out of offshore wind and looks like sort of free market, capitalistic companies are going head first into offshore wind. How does that change the landscape and what should we be expecting here over the next year or two?

Yolanda Padron: We, we’ve seen a large reduction in the, the workforce in offshore wind in all of these state owned companies that you mentioned. Uh, something that I think will be really interesting to see will be that different approach. Of, you know, having these companies be a bit more like traditional corporations that you see, not necessarily having them, [00:04:00] um, be so tied to whatever politically is happening in the government at the moment, or whatever is happening between governments at a time, um, and seeing exactly what value.

The different aspects of a company are bringing into what that company is making into, um, what, uh, the revenue of that company is, and not just kind of what is, what is considered to be the best way forward by governments. Do you agree? Is that something that you’re sensing too?

Allen Hall: The COP 30 just wrapped down in the rainforest of Brazil, and there has not been a lot of agreement news coming out of that summit.

Uh, I think next year it’s gonna move to Turkey, but Australia’s involved heavily. It was supposed to be in Adelaide at one point and then it’s moved to Turkey. [00:05:00] So there doesn’t seem to be a lot of consensus globally about what should be happening for renewables, and it feels like. The state owned companies are, uh, getting heavily leveraged and losing money trying to get their footing back underneath of them, so they’re gonna have to divest of something to get back to the core of what they were doing.

That’s an interesting development because I think one of the question marks regarding sort of these state owned companies was how fast were they willing to develop the technology? How much risk were they willing to take? Being backed by governments gets a little political at times, right? So they, they want to have a, a steady stream of revenue coming from these operations.

And when they don’t, the politicians step in and, uh, lean on the company is a good bit. Does the move to more, uh, standalone companies that are investing sort of venture capital money and bank money taking loans? I assume most of this [00:06:00] does that. Change how the offshore industry looks at itself. One and two, what the OEMs are thinking.

Because if they were going to sell to an TED or an Ecuador, or a stack raft or vattenfall, any of them, uh, you know, when you’re going to that sales discussion that they’re backed by billions and billions and billions of, of kroner or whatever the, the currency is. So you may not have to. Really be aggressive on pricing.

Now you’re dealing with companies that are heavily leveraged and don’t have that banking of a government. Do you think there’s gonna be a tightening of what that marketplace looks like or more pressure to go look towards China for offshore wind turbines?

Yolanda Padron: It’ll definitely get a bit more audited internally, exactly what decisions are made and and how objective teams are.

I think that there’s. [00:07:00] In all of the companies that you mentioned, there’s some semblance of things that maybe happened because of what was going on politically or, or because of ties that certain governments had to each other, or certain governments had to specific corporations, um, which was a, a great way for those companies to operate at the time and what was, what made sense.

But now that it’s. A third party who genuinely, you know, needs that cash flow in from that business or that part of the business, it’ll, I think you’ll definitely start seeing some, some greater efficiencies going on within

Allen Hall: these teams. Well, I would hope so. If you think about the way the United States moved pre, uh, the current administration.

There were a number of US based companies sort of going 50 50 on a lot of the [00:08:00] offshore development, and then they slowly started backing away. The only one that’s still really in it is Dominion, was the coastal offshore, um, coastal Virginia offshore wind project that is still progressing at a good pace.

But, uh, everybody else that was involved in, and they’re not the same kind of structure as an Ecuador is. They’re not, uh, there’s kinda state-owned entities in the United States and states can’t have deficits, unlike nations can. So the US deficit obviously is massively large, but state deficits don’t really exist.

So those electric companies can’t get highly leveraged where they’re gonna bleed cash. It’s just not a thing. It’s gonna happen. So I think I saw the precursors to some of this offshore turbulence happening in the United States as the. They didn’t see a lot of profit coming from the state electric companies.

That seems to be flowing into Europe now pretty heavily. That started about six months [00:09:00] ago. How are they gonna structure some of these offshore projects now? Are they just gonna put them on hold and wait for interest rates to come down so that the margins go up? Is is that really the play? Is that you have the plot of land?

You already have all the, the filings and the paperwork and authorization to do a project at some point, is it just now a matter of waiting where the time is? Right. Financially,

Yolanda Padron: that question will be answered by each specific company and see what, what makes sense to them. I don’t think that it makes sense to stall projects that if you already have the permits in, if you already have everything in, and just to, to see when the time is right, because.

Everything’s been ramping up to that moment, right? Like, uh, the water’s always already flowing. Um, but it, it’ll, it’ll definitely be interesting to see what approach, like where, where each company finds themselves. I, they’ll have to rely on [00:10:00] what information has come out in the past and maybe try to analyze it, try to see exactly where things went wrong, or try to pinpoint what.

Decisions to not make. Again, knowing what they know now, but with everything already flowing and everything already in queue, it’ll have to be something that’s done sooner rather than later to not lose any of that momentum of the projects because they’re not reinventing the wheel.

Allen Hall: Siemens is developing what a 20 odd megawatt, offshore turbine?

22 megawatt, if I remember right. 21, 22. Something in there. Obviously Ming Yang and some others are talking about upwards of 15 megawatts in the turbine. If you have a lot of capital at risk and not a lot of government backing in it, are you going to step down and stay in the 15 megawatt range offshore because there’s some little bit of history, or are you gonna just roll the dice?

Some new technology knowing that you can get the, the dollar per megawatt [00:11:00] down. If you bought a Chinese wind turbine, put it in the water. Do you roll that? Do you roll that dice and take the risk? Or is the safer bet and maybe the financing bet gonna play out easier by using a Vestus 15 megawatt turbine or a Siemens older offshore turbine that has a track record with it.

Yolanda Padron: I think initially it’ll have to be. Using what’s already been established and kind of the devil, you know? Right. I, I think it’ll, there’s a lot of companies that are coming together and, and using what’s done in the field and what operational information they have to be able to, to. Take that information and to create new studies that could be done on these new blades, on these new technologies, uh, to be able to take that next step into innovation without compromising any [00:12:00] of the, of the money, any of the aspects really like lowering your risk

Allen Hall: portfolio.

Yeah. ’cause the risk goes all the way down to the OEMs, right. If the developer fails and the OEM doesn’t get paid. It, it’s a. Catastrophic down the chain event that Siemens investors are looking to avoid, obviously. So they’re gonna be also looking at the financing of these companies to decide whether they’re going to sell them turbines and.

The question comes up is how much are they gonna ask for a deposit before they will deliver the first turbine? It may be most of the money up front. Uh, it generally is, unless you’re a big developer. So this is gonna be an interesting, uh, turning point for the offshore wind industry. And I know in 2026 we’re gonna see a lot more news about it, and probably some names we haven’t heard of in a while.

Coming back into offshore wind. Don’t miss the UK Offshore Wind Supply Chain Spotlight 2025 in Edinburg on December 11th. Over 550 delegates and 100 exhibitors will be at this game changing event. [00:13:00] Connect with decision makers, explore market ready innovations and secure the partnerships to accelerate your growth.

Register now and take your place at the center of the UK’s offshore Wind future. Just visit supply chain spotlight.co.uk and register today. Well, as we all know, the offshore wind industry has sort of a problem, which is now starting to come more prevalent, which is the first generation of offshore wind turbines that prove that the technology could work at scale or getting old.

We’re also developing a lot of new wind turbines, so the blade links are getting much longer. We don’t have a lot of design history on them. Decommissioning is expensive. Of course, anything offshore is expensive. What if we can make those blades last longer offshore, how would we do that? Well, that question has come up a number of times at many of the, the conferences that I have attended, and it looks like ORI Catapult, which is based in the UK and has their test center [00:14:00] in Blythe, England, is working with Blade Dina, which is a Danish engineering company that’s now owned by Res.

So if you haven’t. Seeing anything from Blade Dina, you’re not paying attention. You should go to the website and check them out. Uh, they have all kinds of great little technology and I call it little technology, but innovative technology to make blades last longer. So some really cool things from the group of Blade Dina, but they’re gonna be working with re catapult to test an 88 meter blade for torsion.

And I’m an electrical engineer. I’m gonna admit it up front, Yolanda. I don’t know a lot about torsional testing. I’ve seen it done a little bit on aircraft wings, but I haven’t seen it done on wind turbine blades. And my understanding, talking to a lot of blade experts like yourself is when you start to twist a blade, it’s not that easy to simulate the loads of wind loads that would happen normally on a turbine in the laboratory.

Yolanda Padron: Absolutely. I think this is going to be so [00:15:00] exciting as someone in operations, traditionally in operations, uh, because I think a lot of the, the technology that we’ve seen so far and the development of a lot of these wind projects has been from teams that are very theory based. And so they’ve, they’ve seen what simulations can be done on a computer, and those are great and those are perfect, but.

As everyone knows, the world is a crazy place. And so there’s so many factors that you might not even think to consider before going into operations and operating this, uh, wind farm for 10, 20 years. And so something that Blade Dina is doing is bringing a lot of that operational information and seeing, like applying that to the blade testing to be able to, to get us to.

The next step of being able to innovate while knowing a little bit [00:16:00]more of what exactly you’re putting on there and not taking as big a risk.

Allen Hall: Does the lack of torsional testing increase the risk? Because if you listen to, uh, a, a lot of blade structure people, one of the things that’s discussed, and Blaina has been working on this for a couple of years, I went back.

Two or three years to see what some of the discussions were. They’ve been working with DTU for quite a while, but Dina has, uh, but they think that some of the aging issues are really related to torsion, not to flap wise or edgewise movement of the blade, if that’s the case, particularly on longer blades, newer blades, where they’re lighter.

If that’s the case, is there momentum in the industry to create a standard on how to. Do this testing because I, I know it’s gonna be difficult. I, I can imagine all the people from Blaina that are working on it, and if you’ve met the Blaina folk, there [00:17:00] are pretty bright people and they’ve been working with DTU for a number of years.

Everybody in this is super smart. But when you try to get something into an IEC standard, you try to simplify where it can be repeatable. Is this. Uh, is it even possible to get a repeatable torsion test or is it gonna be very specific to the blade type and, or it is just gonna be thousands of hours of engineering even to get to a torsion test?

Yolanda Padron: I think right now it’ll be the thousands of hours of engineering that we’re seeing, which isn’t great, but hopefully soon there, there could be some sort of. A way to, to get all of these teams together and to create a bit of a more robust standard. Of course, these standards aren’t always perfect. We’ve seen that in, in other aspects such as lightning, but it at least gets you a starting point to, to be able to, to have everyone being compliance with, with a similar [00:18:00] testing parameters.

Allen Hall: When I was at DTU, oh boy, it’s probably been a year and a half, maybe two years ago. Yikes. A lot has happened. We were able to look at, uh, blades that had come off the first offshore wind project off the coast of Denmark. These blades were built like a tank. They could live another 20, 30 years. I think they had been on in the water for 20 plus years.

If I remember correctly. I was just dumbfounded by it, like, wow. That’s a long time for a piece of fiberglass to, to be out in such a harsh environment. And when they started to structurally test it to see how much life it had left in it, it was, this thing could last a lot longer. We could keep these blades turned a lot longer.

Is that a good design philosophy though? Are should we be doing torsional testing to extend the lifetime to. 40, 50 years because I’m concerned now that the, well, the reality is you like to have everything fall apart at once. The gearbox to fail, the generator to fail, the [00:19:00] blades, to fail, the tower, to fail all of it at the same time.

That’s your like ideal engineering design. And Rosemary always says the same thing, like you want everything to fall apart and the same day. 25 years out because at 25 years out, there’s probably a new turbine design that’s gonna be so much massively better. It makes sense to do it. 20 years is a long time.

Does it make sense to be doing torsional testing to extend the lifetime of these blades past like the 20 year lifespan? Or is, or, or is the economics of it such like, if we can make these turbines in 50 years, we’re gonna do it regardless of what the bearings will hold.

Yolanda Padron: From, from speaking to different people in the field, there’s a lot of appetite to try to extend the, the blade lifetime as long as the permits are.

So if it’s a 50 year permit to try to get it to those 50 years as much as possible, so you don’t have to do a lot of that paperwork and a lot of the, if you have to do [00:20:00] anything related to the mono piles, it’s a bit of a nightmare. Uh, and just trying to, to see that, and of course. I agree that in a perfect world, everything would fail at once, but it doesn’t.

Right? And so there you are seeing in the lifetime maybe you have to do a gearbox replacement here and there. And so, and having the, the blades not be the main issue or not having blades in the water and pieces as long as possible or in those 50 years, then you can also tackle some of the other long-term solutions to see if you, if you can have that wind farm.

For those 50 years or if you are going to have to sort of either replace some of the turbines or, or eat up some of that time left over in the permit that you have.

Allen Hall: Yeah, because I think the industry is moving that way to test gear boxes and to test bearings. RD test systems has made a number of advancements and test beds to do just that, to, [00:21:00] to test these 15, 20, 25 megawatt turbines for lifetime, which we haven’t done.

As much of this probably the industry should have. It does seem like we’re trying to get all the components through some sort of life testing, whatever that is, but we haven’t really understood what life testing means, particularly with blades. Right? So the, the issue of torsion, which is popped its head up probably every six months.

There’s a question about should we be testing for torsion that. Is in line with bearing testing that’s in line with gearbox testing. If we are able to do that, where we spend a little more money on the development side and the durability side, that would dramatically lower the cost of operations, right?

Yolanda Padron: Absolutely. It, it’d lower the cost of operations. It would lower the ask. Now that. A lot of these companies are transition, are [00:22:00]transitioning to be a bit more privatized. It’ll lower the risk long term for, for getting some of those financial loans out, for these projects to actually take place. And, you know, you’ll, you’re having a, a site last 50 years, you’re going to go through different cycles.

Different political cycles. So you won’t have that, um, you won’t have that to, to factor in too much, into, into your risk of whether, whether or not you, you have a permit today and don’t have it tomorrow.

Allen Hall: It does bring the industry to a interesting, uh, crossroads if we can put a little more money into the blades to make them last 25 years.

Pretty regularly like the, the, you’re almost guaranteeing it because of the technology that bleeding that’s gonna develop with Ory Catapult and you get the gearbox and you can get the generator and bearings all to do the same thing. [00:23:00] Are you willing to pay a little bit more for that turbine? Because I think in today’s world or last year’s world, the answer was no.

I wanted the cheapest blade. I wanted the cheapest, uh, to sell. I could get, I wanna put ’em on a tower, I’m gonna call it done. And then at least in the United States, like repower, it’s boom, 10 years it’s gonna repower. So I don’t care about year 20. I don’t even care about year 11, honestly, that those days have are gone for a little while, at least.

Do you think that there’s appetite for say, a 10% price increase? Maybe a 15% say 20. Let’s just go crazy and say it’s a 20% price increase to then know, hey, we have some lifecycle testing. We’re really confident in the durability these turbines is. There’s a trade off there somewhere there, right?

Yolanda Padron: Yeah. I mean, spending 10, 20% of CapEx to it, it.

Will, if you can dramatically increase [00:24:00] the, the lifetime of the blades and not just from the initial 10 years, making them 20 years like we’re talking about, but some of these blades are failing before they hit that 10 year mark because of that lack of testing, right. That we’ve seen, we’ve talked to so many people about, and it’s an unfortunate reality.

But it is a reality, right? And so it is something that if you’re, you’re either losing money just from having to do a lot of repairs or replacements, or you’re losing money from all of the downtime and not having that generation until you can get those blade repairs or replacements. So in spending a little bit more upfront, I, I feel like there should be.

Great appetite from a lot of these companies to, to spend that money and not have to worry about that in the long term.

Allen Hall: Yeah, I think the 20 26, 27, Joel would always say it’s 2027, but let’s just say 2027. If you have an [00:25:00] opportunity to buy a really hard and vested turbine or a new ing y, twin headed dragon and turbine, whatever, they’re gonna call this thing.

I think they’re gonna stick to the European turbine. I really do. I think the lifetime matters here. And having security in the testing to show that it’s gonna live that long will make all the little difference to the insurance market, to the finance market. And they’re gonna force, uh, the developers’ hands that’s coming,

Yolanda Padron: you know, developing of a project.

Of course, we see so many projects and operations and everything. Um, but developing a project does take years to happen. So if you’re developing a project and you think, you know, this is great because I can have this project be developed and it will take me and it’ll be alive for a really long time and it’ll be great and I’ll, I’ll be able to, to see that it’s a different, it’s a different business case too, of how much money you’re going to bring into the [00:26:00]company by generating a lot more and a lot more time and having to spend less upfront in all of the permitting.

Because if instead of having to develop two projects, I can just develop one and it’ll last as long as two projects, then. Do you really have your business case made for you? Especially if it’s just a 10 to 20% increase instead of a doubling of all of the costs and effort.

Speaker 4: Australia’s wind farms are growing fast, but are your operations keeping up?

Join us February 17th and 18th at Melbourne’s Poolman on the park for Wind Energy o and M Australia 2026, where you’ll connect with the experts solving real problems in maintenance asset management. And OEM relations. Walk away with practical strategies to cut costs and boost uptime that you can use the moment you’re back on site.

Register now at W om a 2020 six.com. Wind Energy, o and m Australia is created [00:27:00] by Wind professionals for wind professionals. Because this industry needs solutions, not speeches,

Allen Hall: I know Yolanda and I are preparing to go to Woma Wind Energy, o and m Australia, 2026 in February. Everybody’s getting their tickets and their plans made.

If you haven’t done that, you need to go onto the website, woma WMA 2020 six.com and register to attend the event. There’s a, there’s only 250 tickets, Yolanda, that’s not a lot. We sold out last year. I think it’s gonna be hard to get a ticket here pretty soon. You want to be there because we’re gonna be talking about everything operations and trying to make turbines in Australia last longer with less cost.

And Australians are very, um, adept at making things work. I’ve seen some of their magic up close. It’s quite impressive. Uh, so I’m gonna learn a lot this year. What are you looking forward to at Wilma 26? Yolanda. [00:28:00]

Yolanda Padron: I think it’s going to be so exciting to have such a, a relatively small group compared to the different conferences, but even just the fact that it’s everybody talking to each other who’s seen so many different modes of failure and so many different environments, and just everybody coming together to talk solutions or to even just establish relationships for when that problem inevitably arises without having it.

Having, I mean, something that I always have so much anxiety about whenever I go to conferences is just like getting bombarded by salespeople all the time, and so this is just going to be great Asset managers, engineers, having everybody in there and having everybody talking the same language and learning from each other, which will be very valuable.

At least for me.

Allen Hall: It’s always sharing. That’s what I enjoy. And it’s not even necessarily during some of the presentations and the round tables and the, [00:29:00] the panels as much as when you’re having coffee out in the break area or you’re going to dinner at night, or uh, meeting before everything starts in the morning.

You just get to learn so much about the wind industry and where people are struggling, where they’re succeeding, how they dealt with some of these problems. That’s the way the industry gets stronger. We can’t all remain in our little foxholes, not looking upside, afraid to poke our head up and look around a little bit.

We, we have to be talking to one another and understanding how others have attacked the same problem. And I always feel like once we do that, life gets a lot easier. I don’t know why we’re make it so hard and wind other industries like to talk to one another. We seem somehow close ourselves off. And uh, the one thing I’ve learned in Melbourne last year was.

Australians are willing to describe how they have fixed these problems. And I’m just like dumbfounded. Like, wow, that was brilliant. You didn’t get to to Europe and talk about what’s going on [00:30:00] there. So the exchange of information is wonderful, and I know Yolanda, you’re gonna have a great time and so are everybody listening to this podcast.

Go to Woma, WOMA 2020 six.com and register. It’s not that much money, but it is a great time and a wonderful learning experience. That wraps up another episode of the Uptime Wind Energy Podcast. And if today’s discussion sparked any questions or ideas, we’d love to hear from you. Reach out to us on LinkedIn and don’t for, and don’t forget to subscribe so you never miss an episode.

And if you found value in today’s conversation, please leave us a review. It really helps other wind energy professionals discover the show and we’ll catch you on the next episode of the Uptime Wind Energy Podcast. This time next [00:31:00] week.

https://weatherguardwind.com/statkraft-offshore-torsional/

Renewable Energy

Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage

Published

11 hours ago

February 26, 2026

Alice Rush

Weather Guard Lightning Tech

Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage

This exclusive article originally appeared in PES Wind 4 – 2025 with the title, Operations take center stage in wind’s next chapter. It was written by Allen Hall and other members of the WeatherGuard Lightning Tech team.

As aging fleets, shrinking margins, and new policies reshape the wind sector, wind energy operations are in the spotlight. The industry’s next chapter will be defined not by capacity growth, but by operational excellence, where integrated, predictive maintenance turns data into decisions and reliability into profit.

Wind farm operations are undergoing a fundamental transformation. After hosting hundreds of conversations on the Uptime Wind Energy Podcast, I’ve witnessed a clear pattern: the most successful operators are abandoning reactive maintenance in favor of integrated, predictive strategies. This shift isn’t just about adopting new technologies; it’s about fundamentally rethinking how we manage aging assets in an era of tightening margins and expanding responsibilities.

The evidence was overwhelming at this year’s SkySpecs Customer Forum, where representatives from over 75% of US installed wind capacity gathered to share experiences and strategies. The consensus was clear: those who integrate monitoring, inspection, and repair into a cohesive operational strategy are achieving dramatic improvements in reliability and profitability.

Takeaway: These options have been available to wind energy operations for years; now, adoption is critical.

Why traditional approaches to wind farm operations are failing

Today’s wind operators face an unprecedented convergence of challenges. Fleets installed during the 2010-2015 boom are aging in unexpected ways, revealing design vulnerabilities no one anticipated. Meanwhile, the support infrastructure is crumbling; spare parts have become scarce, OEM support is limited, and insurance companies are tightening coverage just when operators need them most.

The situation is particularly acute following recent policy changes. The One Big Beautiful Bill in the United States has fundamentally altered the economic landscape. PTC farming is no longer viable; turbines must run longer and more reliably than ever before. Engineering teams, already stretched thin, are being asked to manage not just wind assets but solar and battery storage as well. The old playbook simply doesn’t work anymore.

Consider the scope of just one challenge: polyester blade failures. During our podcast conversation with Edo Kuipers of We4Ce, we learned that an estimated 30,000 to 40,000 blades worldwide are experiencing root bushing issues. ‘After a while, blades are simply flying off,’ Kuipers explained. The financial impact of a single blade failure can exceed €300,000 when you factor in replacement costs, lost production, and crane mobilization. Yet innovative repair solutions, like the one developed by We4Ce and CNC Onsite, can address the same problem for €40,000 if caught early. This pattern repeats across every major component. Gearbox failures that once required complete replacement can now be predicted months in advance. Lightning damage that previously caused catastrophic failures can be prevented with inexpensive upgrades and real-time monitoring. All these solutions are based on the principle that predicted maintenance is better than an expensive surprise.

Seeing problems before they happeny, and potential risks

The transformation begins with visibility. Modern monitoring systems reveal problems that traditional methods miss entirely. Eric van Genuchten of Sensing360 shared an eye-opening statistic on our podcast: ‘In planetary gearbox failures, they get 90%, so there’s still 10% of failures they cannot detect.’ That missing 10% represents the catastrophic failures that destroy budgets and production targets. Advanced monitoring technologies are filling these gaps. Sensing360’s fiber optic sensors, for example, detect minute deformations in steel components, revealing load imbalances and fatigue progression invisible to traditional monitoring. ‘We integrate our sensors in steel and make rotating equipment smarter,’ van Genuchten explained.

Other companies are deploying acoustic systems to identify blade delamination, oil analysis for gearbox health, and electrical signature analysis for generator issues. Each technology adds a piece to the puzzle, but the real value comes from integration. The impact of load monitoring alone can be transformative.

As van Genuchten explained, ‘Twenty percent more loading on a gearbox or on a bearing is half of your life. The other way around, twenty percent less loading is double your life.’ With proper monitoring, operators can optimize load distribution across their fleet, extending component life while maximizing production.

But monitoring without action is just expensive data collection. The most successful operators are those who’ve learned to translate sensor data into operational decisions. This requires not just technology but organizational change, breaking down silos between monitoring, maintenance, and management teams.

In Wind Energy Operations, Early intervention makes the million-dollar difference

The economics of early intervention are compelling across every component type. The blade root bushing example from We4Ce illustrates this perfectly. With their solution, early detection means replacing just 24-30 bushings in about 24 hours of drilling work. Wait, and you’re looking at 60+ bushings and 60 hours of work. Early detection doesn’t just prevent catastrophic failure; it makes repairs faster, cheaper, and more reliable.

This principle extends throughout the turbine. Early-stage bearing damage can be addressed through targeted lubrication or minor adjustments. Incipient electrical issues can be resolved with cleaning or connection tightening. Small blade surface cracks can be repaired in a few hours before they propagate into structural damage requiring weeks of work.

Leading operators are implementing tiered response protocols based on monitoring data. Critical issues trigger immediate intervention. Developing problems are scheduled for the next maintenance window. Minor issues are monitored and addressed during routine service. This systematic approach reduces both emergency repairs and unnecessary maintenance, optimizing resource allocation across the fleet.

Turning information into action

While monitoring generates data, platforms like SkySpecs’ Horizon transform that data into operational intelligence. Josh Goryl, SkySpecs’ Chief Revenue Officer, explained their evolution at the recent Customer Forum: ‘I think where we can help our customers is getting all that data into one place.

The game-changer is integration across data types. The company is working to combine performance data with CMS data to provide valuable insights into turbine health. This approach has been informed by operators across the world, who’ve discovered that integrated platforms deliver insights that siloed data can’t.

The platform approach also addresses the reality of shrinking engineering teams managing expanding portfolios. As Goryl noted, many wind engineers are now responsible for solar and battery storage assets as well. One platform managing multiple technologies through a unified interface becomes essential for operational efficiency.

The Integration Imperative for Wind Farm Operations

The most successful operators aren’t just adopting individual technologies; they’re integrating monitoring, inspection, and repair into a seamless operational system. This integration operates at multiple levels.

At the technical level, data from various monitoring systems feeds into unified platforms that provide comprehensive asset visibility. These platforms don’t just display data; they analyze patterns, predict failures, and generate work orders.

At the organizational level, integration means breaking down barriers between departments. This cross-functional collaboration transforms O&M from a cost center into a value driver. Building your improvement roadmap For operators ready to enhance their O&M approach, the path forward involves several key steps:

Assessing the Current State of your Wind Energy Operations

Document your maintenance costs, failure rates, and downtime patterns. Identify which problems consume the most resources and which assets are most critical to your wind farm operations.

Start with targeted pilots Rather than attempting wholesale transformation, begin with focused initiatives targeting your biggest pain points. Whether it’s blade monitoring, gearbox sensors, or repair innovations, starting with your largest issue will help you see the biggest benefit.

• Invest in integration, not just technology: the most sophisticated monitoring system is worthless if its data isn’t acted upon. Ensure your organization has the processes and culture to transform data into decisions – this is the first step to profitability in your wind farm operations.

Build partnerships, not just contracts: look for technology providers and service companies willing to share knowledge, not just deliver services. The goal is building capability, not dependency.

• Measure and iterate: track the impact of each initiative on your key performance indicators. Use lessons learned to refine your approach and guide future investments.

The competitive advantage

The wind industry has reached an inflection point. With increasingly large and complex turbines, monitoring needs to adapt with it. The era of flying blind is over.

In an industry where margins continue to compress and competition intensifies, operational excellence has become a key differentiator. Those who master the integration of monitoring, inspection, and repair will thrive. Those who cling to reactive maintenance face escalating costs and declining competitiveness.

The technology exists. The business case is proven. The early adopters are already reaping the benefits. The question isn’t whether to transform your O&M approach, but how quickly you can adapt to this new reality. In the race to operational excellence, the winners will be those who act decisively to embrace the efficiency revolution reshaping wind operations.

Unless otherwise noted, images here are from We4C Rotorblade Specialist.

Wind Industry Operations: In Wind's Next Chapter, Operations take center stage

Contact us for help understanding your lightning damage, future risks, and how to get more uptime from your equipment.

Download the full article from PES Wind here

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Wind Industry Operations: In Wind’s Next Chapter, Operations take center stage

Renewable Energy

BladeBUG Tackles Serial Blade Defects with Robotics

Published

14 hours ago

February 26, 2026

Alice Rush

Weather Guard Lightning Tech

BladeBUG Tackles Serial Blade Defects with Robotics

Chris Cieslak, CEO of BladeBug, joins the show to discuss how their walking robot is making ultrasonic blade inspections faster and more accessible. They cover new horizontal scanning capabilities for lay down yards, blade root inspections for bushing defects, and plans to expand into North America in 2026.

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

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

Allen Hall: Chris, welcome back to the show.

Chris Cieslak: It’s great to be back. Thank you very much for having me on again.

Allen Hall: It’s great to see you in person, and a lot has been happening at Blade Bugs since the last time I saw Blade Bug in person. Yeah, the robot. It looks a lot different and it has really new capabilities.

Chris Cieslak: So we’ve continued to develop our ultrasonic, non-destructive testing capabilities of the blade bug robot.

Um, but what we’ve now added to its capabilities is to do horizontal blade scans as well. So we’re able to do blades that are in lay down yards or blades that have come down for inspections as well as up tower. So we can do up tower, down tower inspections. We’re trying to capture. I guess the opportunity to inspect blades after transportation when they get delivered to site, to look [00:01:00] for any transport damage or anything that might have been missed in the factory inspections.

And then we can do subsequent installation inspections as well to make sure there’s no mishandling damage on those blades. So yeah, we’ve been just refining what we can do with the NDT side of things and improving its capabilities

Joel Saxum: was that need driven from like market response and people say, Hey, we need, we need.

We like the blade blood product. We like what you’re doing, but we need it here. Or do you guys just say like, Hey, this is the next, this is the next thing we can do. Why not?

Chris Cieslak: It was very much market response. We had a lot of inquiries this year from, um, OEMs, blade manufacturers across the board with issues within their blades that need to be inspected on the ground, up the tap, any which way they can.

There there was no, um, rhyme or reason, which was better, but the fact that he wanted to improve the ability of it horizontally has led the. Sort of modifications that you’ve seen and now we’re doing like down tower, right? Blade scans. Yeah. A really fast breed. So

Joel Saxum: I think the, the important thing there is too is that because of the way the robot is built [00:02:00] now, when you see NDT in a factory, it’s this robot rolls along this perfectly flat concrete floor and it does this and it does that.

But the way the robot is built, if a blade is sitting in a chair trailing edge up, or if it’s flap wise, any which way the robot can adapt to, right? And the idea is. We, we looked at it today and kind of the new cage and the new things you have around it with all the different encoders and for the heads and everything is you can collect data however is needed.

If it’s rasterized, if there’s a vector, if there’s a line, if we go down a bond line, if we need to scan a two foot wide path down the middle of the top of the spa cap, we can do all those different things and all kinds of orientations. That’s a fantastic capability.

Chris Cieslak: Yeah, absolutely. And it, that’s again for the market needs.

So we are able to scan maybe a meter wide in one sort of cord wise. Pass of that probe whilst walking in the span-wise direction. So we’re able to do that raster scan at various spacing. So if you’ve got a defect that you wanna find that maximum 20 mil, we’ll just have a 20 mil step [00:03:00] size between each scan.

If you’ve got a bigger tolerance, we can have 50 mil, a hundred mil it, it’s so tuneable and it removes any of the variability that you get from a human to human operator doing that scanning. And this is all about. Repeatable, consistent high quality data that you can then use to make real informed decisions about the state of those blades and act upon it.

So this is not about, um, an alternative to humans. It’s just a better, it’s just an evolution of how humans do it. We can just do it really quick and it’s probably, we, we say it’s like six times faster than a human, but actually we’re 10 times faster. We don’t need to do any of the mapping out of the blade, but it’s all encoded all that data.

We know where the robot is as we walk. That’s all captured. And then you end up with really. Consistent data. It doesn’t matter who’s operating a robot, the robot will have those settings preset and you just walk down the blade, get that data, and then our subject matter experts, they’re offline, you know, they are in their offices, warm, cozy offices, reviewing data from multiple sources of robots.

And it’s about, you know, improving that [00:04:00] efficiency of getting that report out to the customer and letting ’em know what’s wrong with their blades, actually,

Allen Hall: because that’s always been the drawback of, with NDT. Is that I think the engineers have always wanted to go do it. There’s been crush core transportation damage, which is sometimes hard to see.

You can maybe see a little bit of a wobble on the blade service, but you’re not sure what’s underneath. Bond line’s always an issue for engineering, but the cost to take a person, fly them out to look at a spot on a blade is really expensive, especially someone who is qualified. Yeah, so the, the difference now with play bug is you can have the technology to do the scan.

Much faster and do a lot of blades, which is what the de market demand is right now to do a lot of blades simultaneously and get the same level of data by the review, by the same expert just sitting somewhere else.

Chris Cieslak: Absolutely.

Joel Saxum: I think that the quality of data is a, it’s something to touch on here because when you send someone out to the field, it’s like if, if, if I go, if I go to the wall here and you go to the wall here and we both take a paintbrush, we paint a little bit [00:05:00] different, you’re probably gonna be better.

You’re gonna be able to reach higher spots than I can.

Allen Hall: This is true.

Joel Saxum: That’s true. It’s the same thing with like an NDT process. Now you’re taking the variability of the technician out of it as well. So the data quality collection at the source, that’s what played bug ducts.

Allen Hall: Yeah,

Joel Saxum: that’s the robotic processes.

That is making sure that if I scan this, whatever it may be, LM 48.7 and I do another one and another one and another one, I’m gonna get a consistent set of quality data and then it’s goes to analysis. We can make real decisions off.

Allen Hall: Well, I, I think in today’s world now, especially with transportation damage and warranties, that they’re trying to pick up a lot of things at two years in that they could have picked up free installation.

Yeah. Or lifting of the blades. That world is changing very rapidly. I think a lot of operators are getting smarter about this, but they haven’t thought about where do we go find the tool.

Speaker: Yeah.

Allen Hall: And, and I know Joel knows that, Hey, it, it’s Chris at Blade Bug. You need to call him and get to the technology.

But I think for a lot of [00:06:00] operators around the world, they haven’t thought about the cost They’re paying the warranty costs, they’re paying the insurance costs they’re paying because they don’t have the set of data. And it’s not tremendously expensive to go do. But now the capability is here. What is the market saying?

Is it, is it coming back to you now and saying, okay, let’s go. We gotta, we gotta mobilize. We need 10 of these blade bugs out here to go, go take a scan. Where, where, where are we at today?

Chris Cieslak: We’ve hads. Validation this year that this is needed. And it’s a case of we just need to be around for when they come back round for that because the, the issues that we’re looking for, you know, it solves the problem of these new big 80 a hundred meter plus blades that have issues, which shouldn’t.

Frankly exist like process manufacturer issues, but they are there. They need to be investigated. If you’re an asset only, you wanna know that. Do I have a blade that’s likely to fail compared to one which is, which is okay? And sort of focus on that and not essentially remove any uncertainty or worry that you have about your assets.

’cause you can see other [00:07:00] turbine blades falling. Um, so we are trying to solve that problem. But at the same time, end of warranty claims, if you’re gonna be taken over these blades and doing the maintenance yourself, you wanna know that what you are being given. It hasn’t gotten any nasties lurking inside that’s gonna bite you.

Joel Saxum: Yeah.

Chris Cieslak: Very expensively in a few years down the line. And so you wanna be able to, you know, tick a box, go, actually these are fine. Well actually these are problems. I, you need to give me some money so I can perform remedial work on these blades. And then you end of life, you know, how hard have they lived?

Can you do an assessment to go, actually you can sweat these assets for longer. So we, we kind of see ourselves being, you know, useful right now for the new blades, but actually throughout the value chain of a life of a blade. People need to start seeing that NDT ultrasonic being one of them. We are working on other forms of NDT as well, but there are ways of using it to just really remove a lot of uncertainty and potential risk for that.

You’re gonna end up paying through the, you know, through the, the roof wall because you’ve underestimated something or you’ve missed something, which you could have captured with a, with a quick inspection.

Joel Saxum: To [00:08:00] me, NDT has been floating around there, but it just hasn’t been as accessible or easy. The knowledge hasn’t been there about it, but the what it can do for an operator.

In de-risking their fleet is amazing. They just need to understand it and know it. But you guys with the robotic technology to me, are bringing NDT to the masses

Chris Cieslak: Yeah.

Joel Saxum: In a way that hasn’t been able to be done, done before

Chris Cieslak: that. And that that’s, we, we are trying to really just be able to roll it out at a way that you’re not limited to those limited experts in the composite NDT world.

So we wanna work with them, with the C-N-C-C-I-C NDTs of this world because they are the expertise in composite. So being able to interpret those, those scams. Is not a quick thing to become proficient at. So we are like, okay, let’s work with these people, but let’s give them the best quality data, consistent data that we possibly can and let’s remove those barriers of those limited people so we can roll it out to the masses.

Yeah, and we are that sort of next level of information where it isn’t just seen as like a nice to have, it’s like an essential to have, but just how [00:09:00] we see it now. It’s not NDT is no longer like, it’s the last thing that we would look at. It should be just part of the drones. It should inspection, be part of the internal crawlers regimes.

Yeah, it’s just part of it. ’cause there isn’t one type of inspection that ticks all the boxes. There isn’t silver bullet of NDT. And so it’s just making sure that you use the right system for the right inspection type. And so it’s complementary to drones, it’s complimentary to the internal drones, uh, crawlers.

It’s just the next level to give you certainty. Remove any, you know, if you see something indicated on a a on a photograph. That doesn’t tell you the true picture of what’s going on with the structure. So this is really about, okay, I’ve got an indication of something there. Let’s find out what that really is.

And then with that information you can go, right, I know a repair schedule is gonna take this long. The downtime of that turbine’s gonna be this long and you can plan it in. ’cause everyone’s already got limited budgets, which I think why NDT hasn’t taken off as it should have done because nobody’s got money for more inspections.

Right. Even though there is a money saving to be had long term, everyone is fighting [00:10:00] fires and you know, they’ve really got a limited inspection budget. Drone prices or drone inspections have come down. It’s sort, sort of rise to the bottom. But with that next value add to really add certainty to what you’re trying to inspect without, you know, you go to do a day repair and it ends up being three months or something like, well

Allen Hall: that’s the lightning,

Joel Saxum: right?

Allen Hall: Yeah. Lightning is the, the one case where every time you start to scarf. The exterior of the blade, you’re not sure how deep that’s going and how expensive it is. Yeah, and it always amazes me when we talk to a customer and they’re started like, well, you know, it’s gonna be a foot wide scarf, and now we’re into 10 meters and now we’re on the inside.

Yeah. And the outside. Why did you not do an NDT? It seems like money well spent Yeah. To do, especially if you have a, a quantity of them. And I think the quantity is a key now because in the US there’s 75,000 turbines worldwide, several hundred thousand turbines. The number of turbines is there. The number of problems is there.

It makes more financial sense today than ever because drone [00:11:00]information has come down on cost. And the internal rovers though expensive has also come down on cost. NDT has also come down where it’s now available to the masses. Yeah. But it has been such a mental barrier. That barrier has to go away. If we’re going going to keep blades in operation for 25, 30 years, I

Joel Saxum: mean, we’re seeing no

Allen Hall: way you can do it

Joel Saxum: otherwise.

We’re seeing serial defects. But the only way that you can inspect and or control them is with NDT now.

Allen Hall: Sure.

Joel Saxum: And if we would’ve been on this years ago, we wouldn’t have so many, what is our term? Blade liberations liberating

Chris Cieslak: blades.

Joel Saxum: Right, right.

Allen Hall: What about blade route? Can the robot get around the blade route and see for the bushings and the insert issues?

Chris Cieslak: Yeah, so the robot can, we can walk circumferentially around that blade route and we can look for issues which are affecting thousands of blades. Especially in North America. Yeah.

Allen Hall: Oh yeah.

Chris Cieslak: So that is an area that is. You know, we are lucky that we’ve got, um, a warehouse full of blade samples or route down to tip, and we were able to sort of calibrate, verify, prove everything in our facility to [00:12:00] then take out to the field because that is just, you know, NDT of bushings is great, whether it’s ultrasonic or whether we’re using like CMS, uh, type systems as well.

But we can really just say, okay, this is the area where the problem is. This needs to be resolved. And then, you know, we go to some of the companies that can resolve those issues with it. And this is really about played by being part of a group of technologies working together to give overall solutions

Allen Hall: because the robot’s not that big.

It could be taken up tower relatively easily, put on the root of the blade, told to walk around it. You gotta scan now, you know. It’s a lot easier than trying to put a technician on ropes out there for sure.

Chris Cieslak: Yeah.

Allen Hall: And the speed up it.

Joel Saxum: So let’s talk about execution then for a second. When that goes to the field from you, someone says, Chris needs some help, what does it look like?

How does it work?

Chris Cieslak: Once we get a call out, um, we’ll do a site assessment. We’ve got all our rams, everything in place. You know, we’ve been on turbines. We know the process of getting out there. We’re all GWO qualified and go to site and do their work. Um, for us, we can [00:13:00] turn up on site, unload the van, the robot is on a blade in less than an hour.

Ready to inspect? Yep. Typically half an hour. You know, if we’ve been on that same turbine a number of times, it’s somewhere just like clockwork. You know, muscle memory comes in, you’ve got all those processes down, um, and then it’s just scanning. Our robot operator just presses a button and we just watch it perform scans.

And as I said, you know, we are not necessarily the NDT experts. We obviously are very mindful of NDT and know what scans look like. But if there’s any issues, we have a styling, we dial in remote to our supplement expert, they can actually remotely take control, change the settings, parameters.

Allen Hall: Wow.

Chris Cieslak: And so they’re virtually present and that’s one of the beauties, you know, you don’t need to have people on site.

You can have our general, um, robot techs to do the work, but you still have that comfort of knowing that the data is being overlooked if need be by those experts.

Joel Saxum: The next level, um, commercial evolution would be being able to lease the kit to someone and or have ISPs do it for [00:14:00] you guys kinda globally, or what is the thought

Chris Cieslak: there?

Absolutely. So. Yeah, so we to, to really roll this out, we just wanna have people operate in the robots as if it’s like a drone. So drone inspection companies are a classic company that we see perfectly aligned with. You’ve got the sky specs of this world, you know, you’ve got drone operator, they do a scan, they can find something, put the robot up there and get that next level of information always straight away and feed that into their systems to give that insight into that customer.

Um, you know, be it an OEM who’s got a small service team, they can all be trained up. You’ve got general turbine technicians. They’ve all got G We working at height. That’s all you need to operate the bay by road, but you don’t need to have the RAA level qualified people, which are in short supply anyway.

Let them do the jobs that we are not gonna solve. They can do the big repairs we are taking away, you know, another problem for them, but giving them insights that make their job easier and more successful by removing any of those surprises when they’re gonna do that work.

Allen Hall: So what’s the plans for 2026 then?

Chris Cieslak: 2026 for us is to pick up where 2025 should have ended. [00:15:00] So we were, we were meant to be in the States. Yeah. On some projects that got postponed until 26. So it’s really, for us North America is, um, what we’re really, as you said, there’s seven, 5,000 turbines there, but there’s also a lot of, um, turbines with known issues that we can help determine which blades are affected.

And that involves blades on the ground, that involves blades, uh, that are flying. So. For us, we wanna get out to the states as soon as possible, so we’re working with some of the OEMs and, and essentially some of the asset owners.

Allen Hall: Chris, it’s so great to meet you in person and talk about the latest that’s happening.

Thank you. With Blade Bug, if people need to get ahold of you or Blade Bug, how do they do that?

Chris Cieslak: I, I would say LinkedIn is probably the best place to find myself and also Blade Bug and contact us, um, through that.

Allen Hall: Alright, great. Thanks Chris for joining us and we will see you at the next. So hopefully in America, come to America sometime.

We’d love to see you there.

Chris Cieslak: Thank you very [00:16:00] much.