Statkraft Withdraws from Floating, Repair Quality Concerns
We discuss Statkraft’s withdrawal from floating wind projects in Norway, Valero’s $23 million Series A funding, and the varying quality of blade repairs in the field. The Babbitt Ranch wind farm is this week’s Wind Farm of the Week.
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. Allen Hall, Joel Saxum, Phil Totaro, and Rosemary Barnes.
Allen Hall: Welcome back to the Uptime Wind Energy Podcast.
I have Phil Totaro from California and Joel Saxum down in Austin, Texas. And Rosemary Barnes will join us shortly from the Southern Hemisphere. Uh, a number of news articles this week that we want to talk about Stack Craft. Let’s lead off there, up in Norway. So Norwegian energy giant Stack Craft has announced it will withdraw from the upcoming floating wind tenor for the U Sierra North area as part of a broader cost cutting strategy.
Uh, the company, which is Europe’s largest renewable energy operator, we’re also halt new offshore wind project [00:01:00] development to focus on what CEO, uh, Bergit Ringsted AL calls near term profitable. Strategies unquote. Like solar? No. Come on, solar, wind. There we go. And batteries In fewer markets the decision follows.
Stack craft’s early announcement and may stop New green Hydrogen developments signaling a strategic shift toward more immediately profitable renewable energy investments fill. Does this slow down some of the offshore wind work, particularly up in Norway, and it does seem like. Floating will be the future here, but if Stack craft’s not gonna be involved and it’s right in their backyard, uh, what does this say to the industry?
Phil Totaro: It doesn’t send the best signal, but it’s also coming in a time when, you know, as we record this, the, the Norwegians just released, uh, four new, uh, wind lease areas with potentially up to 20 different, uh, project [00:02:00] sites. So. It seems like there’s a lot of enthusiasm and obviously they’ve got the wind resource up there to be able to do a lot of floating offshore wind.
If they can work out with their military, you know, the radar interference and all that, uh, there’s no reason they shouldn’t want this capacity because it’s, you know, power that they can use to balance their hydro and power that they can offload to, you know, other Scandinavian countries because there’s plenty of transmission already and they’re, they’re already.
Planning on building more. So, um, it’s just whether or not they have the appetite to put the market mechanisms in place to, to actually support these, uh, you know, these, these tenders.
Joel Saxum: I think appetite’s the right term here, Phil, when you say that because, uh, you know, and as the CEO is saying in this, in this article we’re getting, we’re gonna focus more on near term profitable technologies.
So doing things that they know make money, that are proven to make money. You know, we all love the idea of floating [00:03:00] wind, which is, you know, what they’re, they’re pulling out of this project, your floating wind project. However, nothing’s really so sussed out yet. Nothing’s really sorted. There’s not a specific foundation that works best.
There’s not, uh, a, you know, an interconnect that works best. There’s not a turbine model that’s out there that this is the one, this is what we run with. You don’t have support from major OEMs like, you know, oh, do we pick a Siemens one or a Vestas one, a GE one for offshore? Like we have for fixed bottom offshore.
So I get it like in, in, you know, we’re in a stress capital market where we’re still sitting on high interest rates and, and everybody wants to do something that’s more profitable for them. That’s proven right now, um, in my mind is a good strategy. You know, it would be, you don’t want ’em to pull out of it.
You would love to see some of the, the big guys put some of their r and d budgets and keep this floating thing moving. ’cause that’s a good move for the future. But. I mean, it’s all about making money and, and, and de-risking yourself. So like it’s understandable.
Allen Hall: Well, is [00:04:00] still involved in that URA North effort and they’re working on one of the larger float taste floated wind turbine projects off the coast of Scotland.
Green Volt, right? Yeah. Green Volt. Right. And I’m wondering if CRA feels. Like the technology isn’t developed as far as they would like it to be, and companies like Farrun, which are really heavily involved in floating, are going to do the dirty work and then everybody else is gonna follow behind their lead.
Joel Saxum: Yeah, that could be right. Because that’s what, that’s what’s needed. Someone needs to go and put the money in this and, but it’s going to be risky. Right? So it’s what’s your, what’s your risk appetite? Um, and if we’re talking about risk and offshore wind, I mean, we’ve seen what’s happened in the last six months, a year, so someone has to really.
Uh, I, I guess the, the joke term in Wisconsin, we says, pull, pull up your big boy pants and, and go and go make this happen. So maybe that is, that is of, of our gro We’ve, you know, we’ve spoke with them on the podcast and that’s what they’re focusing on. So maybe it takes someone like them to [00:05:00] really make this thing happen.
Allen Hall: Well, Gros at the minute is it’s discussing what type of term they wanna put offshore. This is where the Ing Yang discussion comes into play, because rag is. I don’t know if they’ve selected them or down selected Bing Yang as one of the potential providers of turbines, but that’s created a lot of chaos, at least temporarily in the UK because the United States is super concerned about a Chinese wind turbine off the
Phil Totaro: coastline of the uk.
Joel was talking about de-risking, uh, and originally for this project, stat Craft was partnered with uh, ocean Winds, which is, um. Uh, EDPR and Eng g and Acre, uh, which was originally mainstream offshore when they originally, um, started making the, the bids and those two, uh, other groups or three technically, if you know, um, Eng G and, and EDPR.
As well as Acre. They had [00:06:00] already previously pulled out of this partnership, so you didn’t have, you don’t have this, this de-risking capability anymore. Stat Craft was basically having to take this whole thing on by themselves, and they probably weren’t finding any other partners that were particularly interested in diving in.
With them at that point. So I think, you know, them pulling the plug, it’s, it’s almost like what happened. Um, you know, when, uh, with the Atlantic Shores project in the United States, you know, when, when one partner pulls out, the other partner can’t really make it a go, so the other partner is gonna pull the plug and then the whole project is basically dead.
So. That’s just what happens. Unfortunately, when you’re not able to de-risk the project
Allen Hall: Over in the uk, they’re de-risking a couple of larger projects. The Crown of State has selected Ecuador and Gwent Glass, which is a joint venture between EDF and ESB. Uh, they’ve been selected as the preferred bidders for floating wind projects in the Celtic Sea.[00:07:00]
Now, each developer was awarded 1.5 gigawatts of capacity. Which is quite a bit in their respective development areas for an annual option fee of 350 pounds per megawatt. And the Crown Estate launched this fifth offshore wind leasing round in February of last year. Originally offering three areas with up to 4.5 gigawatts total capacity.
This is a big deal because you’re bringing in Ecuador and E-D-F-E-S-B. And it’s going to really expand the amount of energy produced from Floating Winds. So, although, um, stack Craft is not gonna be involved up north off the coast of Norway, a bunch of developers are gonna be really involved off the coast of the uk.
This has implications. I think the, the floating wind difficulty, at least the engineering difficulty is gonna be solved by the United Kingdom and maybe France, [00:08:00] don’t you think, Phil?
Phil Totaro: Yeah, I mean, France has had, you know, a couple of demonstration projects now, um, for a little while, and they just got their first kind of, people still refer to it as kind of pre-commercial.
It’s like 30 megawatts worth of, uh, floating offshore capacity now with, uh. A small, small project. Um, and the second one’s on the way, uh, Japan’s been investigating floating foundation technology. We’ve even had some, some stuff here in the States with the University of Maine looking at this. I mean, everybody’s been looking at floating for 15 years.
Um, but the reality of it is, it’s. There’s plenty of technical solutions out there. None of them have achieved commercial viability yet because nobody’s been willing to invest in scaling it up. Um, and the fact that we haven’t really directly involved the oil and gas companies who have, you know, abundant experience with tension like platforms, uh.
Bill confounds [00:09:00] me because, you know, if you, if you leverage the capabilities that they already have, you’re gonna get them more interested because it’s gonna give them an opportunity to leverage the technology that they already have heavily invested in, um, that we can use for, for, you know, a floating offshore wind platform.
So it, it’s always been a bit head scratching the way that the industry’s gone about floating, but. Absolutely. You know, the, the uk um, France and Japan are probably the three likeliest candidates to, to do the majority of the risk reduction on, uh, that technology platform that’s gonna allow it to scale up and, and become more useful in the rest of the world.
Joel Saxum: Feel like completely agree with you. Uh, we’ve been talking about that for a while, right? Um, why are these, some of these companies not getting involved? And the one that I have seen get involved is French company. I. Technique. Used to be technique FMC, uh, they invested in X one wind. And if you know anything about technique, technique is.[00:10:00]
Man, when they were FFMC, they had 50,000 employees worldwide, but they do some of the largest offshore oil and gas installations around the world. Deep water, shallow water, construction, you name it. They even have their own vessels to do construction, like they’re that big. Um, and the engineering power that they have is, it’s massive.
And they’re a French company. So French, EDF, the, the Northern France kind of demonstrated projects and what it was technique energy’s invested in. Um. It was X one, wind XX one, like one of the platform things like, hey, about 10 or 20% of that thing. I don’t remember exactly what it was, maybe 15% of it. Um, but I expected some of that, like those plays to continue on some of like, you know, the SI PEs and more of like the acres and that to get involved more heavily on the, on the innovation side because that’s what they’ve done in oil and gas, right?
They’ve done the, the pre-feed work to make these things happen in deep water. So. They have the engineering prowess, the experience, and the the know-how to do these things. And it’s just kind of like, [00:11:00] where are they at? Why aren’t they playing? You know, why aren’t they planning at a bigger level? Is that, that’s my question.
Allen Hall: Well, is it happening behind the scenes that we just haven’t heard of it yet? Because that’s the feeling for as much money as being poured into these projects, there must be a technical solution. At least validated on the engineering side, you’d think. I
Joel Saxum: did see a press release just the other day. There was a company called en and EN was making a, basically what they described as A-A-U-S-B-C type connection for, for mooring and power connection for floating wind.
So it was like an in a universal, like this is how you plug it in, this is how you connect it. It mores it, it sends power controls, all this stuff. Great technology. They just had, they were just. Purchased, I think by, um, Aurora Energy Services, and Aurora is another one of those players that, that does the dev, that does a lot of dev work offshore.
So you’re seeing some of these technologies get to a certain level, and I don’t know what that technology was, if it was TRO four, TRO six, I don’t know, [00:12:00] but they were scooped up and that that now that IP rest was in a larger offshore development company that could make a move with some of these things.
So. There is some of that stuff, like you said, going on behind the scenes, Alan, I’m sure. Um, we just haven’t seen it that much. If, if anybody wants to talk, call us ’cause we would gladly have you on the podcast.
Allen Hall: It, it does seem like there’s a number of transactions happening that are quiet, that when you piece them all together looks like a solution and I’m glad to hear it as wind energy professionals staying informed is crucial and let’s face it difficult.
That’s why the Uptime podcast recommends PES Wind Magazine. PES Wind offers a diverse range of in-depth articles and expert insights that dive into the most pressing issues facing our energy future. Whether you’re an industry veteran or new to wind, PES Wind has the high quality content you need. Don’t miss out.
Visit PS win.com today. If you haven’t downloaded your latest [00:13:00] PES WIN magazine, you need to do that now. It’s free and it’s full of great articles. Uh, I wanna highlight one from FT. Technologies. So if you haven’t heard FT Technologies, and I don’t know you believe, or Rock, uh, Ft. Technologies makes the, uh, the, I wouldn’t call it an ultrasonic.
Wind speed sensor, but it uses sort of ultrasound to create a standing wave that that can then detect, uh, wind speeds very accurately. So it doesn’t have the little nanometer spinny piece to it. It, there’s no moving parts, which makes it so elegant and simple and it measures, uh, wind speed very accurately.
In fact, it can me measure wind speed’s up to Joel now. Hold on. 200 miles per hour.
Joel Saxum: Wait, I, I hope we’re not seeing those at a wind farm, to be honest with you. Um, but I, but I think that though, there’s something that’s really important here that I would love to see more of. Components in the wind industry go to [00:14:00] classical, an anemometer, and I might say that wrong.
Allen Hall: Anemometer,
Joel Saxum: they’re moving, right? It’s a moving part. Like you see ’em, like you can, you could buy the weather station for your house. It looks the same as the old school ones that are on these turbines that sit there and spin. You remove that, that o and m risk by using the FT technology sensors, right?
There’s no moving, there’s no moving parts. They’re, you know, they’re not gonna get affected by ice or snow buildup or heavy rains or like dust or like, there’s. There or lightning, there’s no bearings inside of it to go out. Right. So what we’re, what they have done here is something that we should be focusing as an industry on all things wind industry, wind energy is low maintenance, something that just goes out there and works.
And that’s what I like to see.
Allen Hall: Well, there are OEMs that don’t use FT. Technologies. Ologies. Anemometer sensors, which is insane. Oh yeah. That would be an, that would be
Joel Saxum: in a turbine, RFP if I was writing one.
Allen Hall: Right, exactly. If it, if it doesn’t come with a turbine, you need to specify it. And if you’re in a repower situation, you [00:15:00] need to dump the spinny anemometer thingy and put Ft technologies on your turbine because who wants bad anemometer?
Wind measurements? I, Joel, you and I’ve seen it, and you go to the OM buildings, a lot of times there’s a whole pile of broken anemometers on the, of the spinning kind, because they either fail from lightning or the bearings have gone bad or something has happened. Why would you even mess with it? Just buy the right technology.
It’s proven that they’ve been around a long time. Ft. Technologies read the article. Go to PES Wind. Download your copy of PES Wind UH, magazine. You won’t regret it. Swiss Aero Robotics Company, Valero has raised $23 million in series A funding to scale. Its autonomous inspection robots for industrial infrastructure.
Now, Joel, you have visited their facilities in Switzerland, correct? Uh, and we’ve had ’em on the podcast. Valero makes the drone that can do ultrasonic measurements, but also can. [00:16:00] Do resistance measurements on your lightning protection system. The robot is pretty cool ’cause it kind of can orient itself in in any direction.
And then it can apply force on sensors, which you totally need so it can replace a technician, the. The approach is really slick. $23 million is a lot of money. That, that’s would say there’s, uh, a reasonable growth, a reasonable growth pattern for Valero to receive that kind of funding.
Joel Saxum: Yeah, absolutely. I visited the team, like you said last, uh, I think it was last spring.
I was over in their offices in, in Zurich there. Um, and I’ll tell you what, $23 million is gonna go a long ways for this team. They had, they had a great office, uh, set up with kind of the front office meeting spaces and a lot of tech room, right? A ton of space for developers. A really cool glass enclosed kind of, um, test facility where you could watch the tests real time as a, as a viewer through glass.
And they’re flying the drones inside. A lot of really neat things. But [00:17:00]one of the reasons that they’re, they’re of course gonna be able to expand really well, is we like what they do for wind, right? They have the LPS inspection. Uh, technology where they, it’s semi-autonomous. They can go up that once they see the receptor, they can just hit a button and it will semi autonomously, uh, orient the drone in the right way so it gets the right pressure on the blade.
Fantastic. They can also do NDT, but we’re just talking about wind ’cause that’s what we like ’em from. They do a lot of things for all kinds of industrial inspections. So oil and gas, uh, traditional power, you name it, manufacturing facilities. Um, they can inspect it all. So, uh, kudos to the team over there.
Uh, I know they’ve been making some inroads into the states. We’ve heard a lot about, uh, some of the LPS testing they’ve done in the wind sector. Um, and yeah, like I said, $23 million is a lot of money gonna go a long ways for these guys, so, so congratulations.
Allen Hall: Where do you think the majority of their income is gonna come from now?
Is it gonna come from oil and gas and all the measurements they’re doing on steel tanks and, and that sort of. Product.
Joel Saxum: It’s NDT and Oil and [00:18:00] Gas, it’s NDT and oil and Gas. And, and, and the, and the way that they’ve set the Valero, Valero as a company, the Valero t drone, it, it’s really, you set up for NDT Well, because it’s a, it’s a platform, right?
So it’s a platform. You can put a phase array unit, you can put a different, you know, single, single phase unit on it. You can put all kinds of different technologies and they are actively integrating all kinds of different technologies because if you know anything in a non-destructive testing space. Um, it’s all about like, Hey, we’ve got this problem.
We need this type of kit. We got this problem, we need this type of kit. You know, we need to be able to see through, uh, paint coating. So we need phased array. We need, we’re on bare steel so we can use this. We’re on a composite, so we need this. And they’ve done a really good job at setting that system up to be able to utilize all of those technologies.
Um, so yeah, I think that they’ll. And let’s be honest, oil and gas companies pay more. So that’s a good space to be in.
Allen Hall: So let’s put this in perspective with the aeros. Uh, was it series B [00:19:00] with Aeros and then with Valero getting their series A. For the longest time in wind, there wasn’t the last couple of years, there hasn’t been a lot of investment from outside companies into Windish companies, but the robotic sector still seems to be humming quite nicely.
Joel Saxum: Don’t forget 20 million for Sky Specs last fall either. Exactly. So you’re seeing Sky Skys specs with new drone technology. They’ve got the new four site drone out. They’ve got their internal crawlers moving. Eros has got internal crawler Gen three I think it is. Plus all the crazy things that they’re doing.
Robotics, LEP, blade repair, AI integration, really cool stuff. So Y Combinator, of course, if you’re in the startup space or startup networks, you kind of know Y Combinator, they’re, they’re cream of the crop type platform to launch. They put out a list every year that says, this is what we’d like to see from people applying to the Y Combinator.
I think they’re on like Y Combinator, cohort 20 something or whatever. And if you look at that, it was AI and [00:20:00] robotics. Every request, that’s what they wanted. AI and robotics. AI and robotics. So it’s not just AI and robotics in the wind space that we’re seeing the sky specs, the Valero Theones getting the money.
That is a larger trend in the investment world. What
Allen Hall: do you think the market cap is for the robotic repair business? In wind alone, it depends who cracks the ability to do cat five repairs first. You think that’s gonna be the marker?
Joel Saxum: I think if you can c if you can, if you can s ’cause right now you can’t do a robot as it sits today.
I don’t care whose robot it is, cannot do everything a technician can do. So you still need technicians and that will be a, that, that will be that way for a while. I, I think, um, it’s going to be hard to get to the point where we’re doing cat five robotic repairs. Um, I think it’s gonna happen for sure. I think probably Aeros is the closest.
Right? But once you can do that,
Allen Hall: isn’t the aeros approach is to catch. Problems, especially blade repair problems at sort of Cat two and CAT three and [00:21:00] not let it to get to Cat four and five because the robotic solution is so much simpler.
Joel Saxum: Well, I think that’s everybody’s solution, right? Everybody would like to do that.
Catch it at Cat two and three.
Allen Hall: The problem with the Cat two, cat three catches that you just don’t have enough technicians to go out and do it, and the the pricing isn’t right. And I, we might as well discuss it because it’s the, um, discussion of Weather Guard at the minute is. How much quality is going into some of these repairs in the states?
I, I will leave, I will leave the rest of the world out of it for a minute. I think in the United States the quality varies quite a bit and, and the composite repairs, I’m not supremely confident, uh, that we’re getting the. Best repairs that we could for the money we’re spending. Maybe that’s the way to phrase it.
Phil Totaro: Well, but is that because they are triaging? [00:22:00]
Allen Hall: I don’t think that’s it, Phil. I, I think it’s a skill level and just a knowledge.
Joel Saxum: I, it’s, so, so that’s what I wanna bring, uh, I’m gonna mention our friend Alfred Crabtree Blade Blade Repair Academy, because he knows a ton of this stuff, right? And he’s told me, you know, basically for someone on ropes or someone in the field.
Five years is about max. You see someone that’s been on ropes for seven, eight years, they’re a dinosaur, right? So, but, but now let’s, let’s switch that to, uh, and something simple that we all understand. A car, a car repair technician. So you bring your vehicle in to get fixed. A lot of times that technician’s been wrenching for 15, 20 years.
Those are the people that know this stuff right there. There’s a bunch of experience there. They’re not gonna throw someone who’s been, uh, you know, working on cars for a year to switch your engine out or to do a, you know, but that, but that happens, right? Like I, I talked to someone in the field the other day and that was a rope tech, and this was his, his [00:23:00] second summer.
This, this gentleman was fantastic. Met him in the field. He walked out out of their, uh, rope access exclusion zone, did a JSA before we even approached it was, he was awesome. However, second year technician and he was doing a CAT four repair. Uh, that to me is like, whew.
Allen Hall: It’s a little scary. And, and in Europe they don’t tend to treat it that way.
They’re, it tends to be a much longer cycle of working in wind turbine and blade repair. You see a lot of technicians come over from Europe that have. More than five years, generally speaking, and those are, the technicians get assigned to these more complicated tasks.
Rosemary Barnes: There’s a huge difference in working conditions between the US and Europe.
Actually, uh, one time when I was doing a training course in Sweden, I think it was like an advanced hub rescue training course. There was a guy there who had worked, um, as a wind turbine technician in the us and he was upset because he didn’t get enough time with his family. [00:24:00] Basically. He was just on the road all the time.
So he took a job in Sweden instead. So he would be able to see his family in America more because he got, you know, six weeks annual leave and a lot of public holidays and, and all that sort of thing. Proper sick leave as well. Um, and you know, they are actually in Europe worried about your, um. Y you, you know, making sure that you don’t wear your body out in, in four or five years doing a hard job.
You know, they, um, it’s still hard work there. It’s not like it’s ever gonna be an easy job, but in general, they care more about making sure that you don’t get sick from work and even often that you enjoy your work. You know, like that, that, that’s actually an important, um, thing. So we can argue about, um, where Europe is at relative to the US in terms of, um.
Competitiveness and, you know, the hunger to get, uh, you know, innovative startups to work. And so I don’t think it’s like Europe is all better and the US is all worse. But it doesn’t surprise me at all that you would have a short, [00:25:00] short lifespan in a hard job like wind turbine technician in the US compared to compared to Europe.
Allen Hall: Don’t let blade damage catch you off guard. OGs, ping sensors detect issues before they become expensive, time consuming problems. From ice buildup and lightning strikes to pitch misalignment in internal blade cracks. OGs Ping has you covered The cutting edge sensors are easy to install, giving you the power to stop damage before it’s too late.
Visit eLog ping.com and take control of your turbine’s health today.
Phil Totaro: Alan asked the question before, how big is this market? If you’re just talking about inspections, that’s a few hundred million a year. But like Joel mentioned, if you’re talking about being able to do repairs all the way up through Cat four and eventually cat five, that’s gonna end up being worth, you know, several billion.
I mean, just blade repair alone in the United States is on an annual basis about 1.2 to 1.3 billion a year. [00:26:00] So, you know, there’s, there’s certainly a market for this.
Joel Saxum: I, I think Alan, you, you started this conversation about, you know, what are we seeing in the field and is it, is it up to snuff? And I got, I gotta say in generally no, from my seat, no.
Um, I don’t, I don’t think that, yeah, I don’t think that we’re getting the best quality in the field that we, we should in general,
Allen Hall: which opens up the door to robots.
Rosemary Barnes: I do anecdotally, um, hear people, you know, concerned that the same blade that was repaired a couple of years ago is now having a repair in. A very similar place and, um, you know, but no one’s ever, no one’s ever really sure if that’s the exact same problem or something similar because they don’t document well enough.
I don’t think it’s a problem that, you know, someone with two years experience is doing a cat four repair. That, that, to me, there’s nothing wrong with that. If it, the processes are well, well designed and well, um, like the work instructions are all good and the quality control process is appropriate. Uh, [00:27:00] you know, like category four versus category two, it’s only usually, you know, a difference in the number of layers that you’ve gotta remove or just like, how important It’s that you get it right, but honestly, you should be getting it right e every time, no matter what, you know, how severe that the, the damage was.
There’s no. There’s no reason not to. It’s not faster really to do a, um, you know, a bad repair than a, a good one. Um, well, I mean, I guess it depends on what kind of bad repair you do. You, you could, you could do, you, you could just whack a bandaid over the top instead of grinding away. I guess that would be a, would be faster.
But anyway, that aside, like, I, I don’t, I don’t think that there’s any problem with that per se, but the implementation of it, if it’s not right, then you could see problems. You don’t. Want processes that mean that you have to rely on individual judgment and remembering to do the right thing and, you know, noticing something that you wouldn’t, you know, you’re not told to notice in the work instruction.
So I think that it’s probably processes that are to blame if you’ve got problems with, [00:28:00] um, repairs needing to be redone rather than specific repairers.
Joel Saxum: But it’s, it’s the same, it’s the same breath too, Rosemary like, that’s great technician wise, but that means that that engineer who designed the process needs to be properly educated, knowledgeable about it and the process.
I can almost guarantee you at these ISPs that there’s not a process engineer reviewing the qa, QC methodology and stuff. It’s kinda like, this is just how we do it.
Rosemary Barnes: The repairs should be certified. What
Joel Saxum: does, what does it, what does that, what does that mean?
Rosemary Barnes: It means that the, yeah, the repair method has been certified to bring the blade back up to design intent.
Allen Hall: OEM won’t even share the instructions. Right? They won’t even tell you what the layup is. The materials, it’s definitely not happening.
Rosemary Barnes: And then for, um, small, small repairs, then, you know, you don’t need OEM involvement. There’s just, you know, like there’s standard, uh, you know, like, um, chafer angles and there’s lots of, lots of standards involved in how much you need to overlap and, and all that sort of thing.
So [00:29:00] for a, a small standard repair. It, you know, e everything is, is straightforward for something complicated where it’s in, you know, on the main laminate or, um, it’s over a web or it’s really huge. You just, you simply do need engineering to make sure that that’s gonna bring your blade back up to design intent.
And if you can’t do that, then, you know, that’s, um, yeah, that’s a big risk you’re taking and I hope people are doing that mindfully, uh, to, you know, the money that they’re saving by going that route is, um, worth the risk that that adds.
Joel Saxum: Yeah, a lot of ’em are basically like, once you get a, a cohort to agree, like, ah, the ISPs engineer says this is how we should do it, and this is how we’ve done it in the past.
And someone from the asset owner says, that looks about right. That’s, uh, what I think we could do too. And they go, all right,
Allen Hall: do it. Are we measuring the quality out in the field somehow?
Rosemary Barnes: I would at least wanna see people keeping track of where, like what blade, what span wise and cord wise location was a repair done and when, and then, you know, keep that in [00:30:00] a database and then making sure that the same ones aren’t coming up over and over.
I think that would be like a really good step to see if you’ve got a problem. I don’t think that you can really start to tell if you’ve got a problem until you’re at least tracking where the, um. Where the damages are across your fleet and doing Let some, you are gonna need some sort of statistical analysis to see if what you’re seeing is, um, random chance or if something is going on.
Allen Hall: Isn’t that what Skys Spec’s Horizon system is doing is tracking repairs and then looking in the future because they’re doing all the inspections, they can see if that repair is held up or not. And I wonder if there’s any numbers. On the amount of repairs that have failed over time.
Joel Saxum: I’m sure I, I think at the bigger operators, the more advanced ones, right?
Like your next arrows, your rws, your edfs, they’re tracking this stuff. Um, EDF for sure, we know Segala, they’re definitely doing that. Um, but the, the mechanism that I’ve seen in, I like this one and it’s not directly an engineering one, and this is the difference. [00:31:00] Uh, COPQ cost support quality. So it as an ISP, if you’re tracking the amount of times you have to go back to fix something from a quality issue, um, you know, when a lot of, a lot of ISPs will give a one year, two year warranty against worksmanship on their things.
They’re not gonna warranty a failure, but they’ll warranty something in general that when you start to track that, that. That metric of cost, support quality on a commercial side, then you start to see, okay, if we do have an engineering problem or not, you can track it that way. So it’s a, it’s a checks and balances, judicial, legislative kind of thing, right?
Where the commercial side can check the engineering side. And if the engineering side hasn’t been checking themselves, um, that COPQ is a good metric to watch it.
Phil Totaro: Everybody has a certain amount of budget that they can spend on operations and maintenance on an annual basis anyway, and so it basically comes down to triage and they’ll decide, you know, I, I [00:32:00] guess what I’m saying is like they’ll do a repair and say that it’s good enough.
And it might not be like factory restored and factory certifiable like Rosie’s talking about, but it’ll be good enough to be able to, to get the turbine back up and running because at the end of the day, they care about availability, not about the quality of a repair or, or if they’re comparing the two, that the availability is always gonna win.
Allen Hall: Joel and I have been talking to a couple of people about this when the production tax credit finally rolls off and Repowering stops at 10 years. Does that change, that type of repair where they’ll just put a, a bandaid on it to get to the 10 years and replace the blade set?
Phil Totaro: Yeah. ’cause then you need ROI outta your blade, your repairs a hundred percent.
And we’re gonna see what, what happens. Although, keep in mind with the PTC, I mean, we’ve been here before where, you know, it goes away, it comes back again and there will be a new administration at some point and a new congress. So just keep that in mind. But in the [00:33:00] meantime, like if they’re talking about ramping it down, that is necessarily gonna reduce the amount of Repowering projects that are commercially viable.
Because some Repowering is just, if they don’t have the full value of the PTC, they can’t do the repowering. So that means they’re gonna either have to life extend, they’re gonna end the project either early or you know, at the planned end of asset life. And that’s gonna be about it. Um, and you’re gonna hope that you get something.
I, I, I think the reason that we’ll see some life extension is because asset owners are gonna wanna try to wait it out to get to the, another Congress that’s gonna extend the PTC again. And that’s what everybody’s kind of banking on at this point. Let’s just play this out
Allen Hall: just for a minute because I, I wanna go back to the market cap discussion.
If PTC rolls off and the repowering rolls off. Does a market cap for robotics then go up significantly?
Joel Saxum: Yeah, [00:34:00] because you’re needed like that. That’s what we’re, we’re, we’re in a bad spot right now. Like we lose PTCs and you can’t all also, you can’t repower and stuff. There’s a lot of, I’m not gonna say distressed assets, but like looking across the bridge at distressed assets out there that have been ran or managed in a certain way that this is just how we do it in the states.
That all of a sudden, uh oh, we’re not gonna be able to repower these things and we gotta run ’em for 20 more years. And there’s a couple companies out here that have assets that have been around the, a lot of assets that have been there. Constellation is one. They have a lot of assets that were COD oh 8 0 9 2011 2012.
They’ve been running them for a long time without repower. That someone like that may be someone to look at, to say like, what’s the strategy here for the long-term play? Because it could change y.
Phil Totaro: Yeah. Although they also have PPAs that are like 40, 50, 60 bucks a megawatt hour. If you only have like a $20 megawatt hour PPA, then you’re probably not.
You’re, you’re freaking out right now because if you don’t have the ability to do a repowering after 10 [00:35:00] years, uh, and replace the blades and refurbish the gearbox and everything, uh, you’re kind of screwed. So that’s, that’s a, a big deal. The wind farmer of
Joel Saxum: the week this week is Babbit Ranch, which is a next era and Salt River project, which is, um, and this is kind of going back to, we were at a CP over in Phoenix.
This wind farm is north of Flagstaff. You don’t see a lot of wind farms up there. Um, but it’s got some cool factoids about it, right? So it’s uh, 50 ge, 3.4 megawatt, one 40 ma rotor machines, and it is on a ranch that’s been in a family operation since 1886, which is pretty cool. Uh, the timeline, uh, looks like initial announcement of this farm was in January 22.
Construction began in March of 23 and full operation mid 24. So this thing’s about a year old right now. Uh, so that it’s on the Bait Ranch. Uh, it, like I said, it’s been a family operation since 1886. Uh, the families, the fourth [00:36:00]generation leader of the family, his name’s Billy Cordasco, they’ve always been thinking about.
Balancing ranching conservation and innovation. So they’ve been looking into wind energy and, uh, renewable energies on this ranch for a while, and they finally pulled the trigger. Um, and part of it is, uh, the, the Salt River Project is the local, uh, power consumption company, but they’re also going to be a Google data center, uh, in the same space.
So. Wind center’s gonna make about nine and a half million dollars in tax revenue, uh, along with 250 temporary construction jobs, which is pretty cool. Um, and it’s gonna power some data centers, which helps Google’s, uh, net zero emissions goals as well. So the Babbitt Ranch, wind Farm up in or down in Arizona.
You’re the wind farm of the week.
Allen Hall: Oh, that’s a really interesting wind farm. That’s an old farm for Arizona, right? 1886. That’s, that’s a while ago. That’s cool. This is gonna do it for the Uptime Wind Energy Podcast. Thanks for joining us. Uh, we’ll see you here next week for [00:37:00] more Adventures in Wind.
https://weatherguardwind.com/statkraft-floating-quality/
Renewable Energy
A Guide for Solar & Battery Storage for Commercial Properties
Renewable Energy
Morten Handberg Breaks Down Leading Edge Erosion
Weather Guard Lightning Tech

Morten Handberg Breaks Down Leading Edge Erosion
Morten Handberg, Uptime’s blade whisperer, returns to the show to tackle leading edge erosion. He covers the fatigue physics behind rain erosion, why OEMs offer no warranty coverage for it, how operators should time repairs before costs multiply, and what LEP solutions are working in the field.
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: Morten, welcome back to the program.
Morten Handberg: Thanks, Allen. It’s fantastic to be back on on, on the podcast. Really excited to, uh, record an episode on Erosion Today.
Allen Hall: Wow. Leading as erosion is such a huge worldwide issue and. Operators are having big problems with it right now. It does seem like there’s not a lot of information readily available to operators to understand the issue quite yet.
Morten Handberg: Well, it, I mean, it’s something that we’ve been looking at for the, at least the past 10 years. We started looking at it when I was in in DONG or as it back in 2014. But we also saw it very early on because we were in offshore environment, much harsher. Uh, rain erosion conditions, and you were also starting to change the way that the, the, uh, the coatings [00:01:00]that were applied.
So there was sort of a, there was several things at play that meant that we saw very early on, early on offshore.
Allen Hall: Well, let’s get to the basics of rain erosion and leading edge erosion. What is the physics behind it? What, what happens to the leading edges of these blades as rain? Impacts them.
Morten Handberg: Well, you should see it as um, millions of, of small fat, uh, small fatigue loads on the coating because each raindrop, it creates a small impact load on the blade.
It creates a rail wave that sort of creates a. Uh, share, share loads out on, uh, into the coating that is then absorbed by the coating, by the filler and and so on. And the more absorbent that your substrate is, the longer survivability you, you’re leading into coating will have, uh, if you have manufacturing defects in the coating, that will accelerate the erosion.
But it is a fatigue effect that is then accelerated or decelerate depending on, uh, local blade conditions.
Allen Hall: Yeah, what I’ve seen in the [00:02:00] field is the blades look great. Nothing. Nothing. You don’t see anything happening and then all of a sudden it’s like instantaneous, like a fatigue failure.
Morten Handberg: I mean, a lot of things is going on.
Uh, actually you start out by, uh, by having it’s, they call, it’s called mass loss and it’s actually where the erosion is starting to change the material characteristics of the coating. And that is just the first step. So you don’t see that. You can measure it in a, um, in the laboratory setting, you can actually see that there is a changing in, in the coating condition.
You just can’t see it yet. Then you start to get pitting, and that is these very, very, very small, almost microscopic chippings of the coating. They will then accelerate and then you start to actually see the first sign, which is like a slight, a braided surface. It’s like someone took a, a fine grain sandpaper across the surface of the plate, but you only see it on the leading edge.
If it’s erosion, it’s only on the center of the leading edge. That’s very important. If you see it on the sides and further down, then it’s, it’s [00:03:00] something else. Uh, it’s not pure erosion, but then you see this fine grain. Then as that progresses, you see more and more and more chipping, more and more degradation across the, the leading edge of the blade.
Worse in the tip of it, less so into the inner third of the blade, but it is a gradual process that you see over the leading edge. Finally, you’ll then start to see the, uh, the coating coming off and you’ll start to see exposed laminate. Um, and from there it can, it can accelerate or exposed filler or laminate.
From there, it can accelerate because. Neither of those are actually designed to handle any kind of erosion.
Allen Hall: What are the critical variables in relation to leading edge erosion? Which variables seem to matter most? Is it raindrop size? Is it tip speed? What factors should we be looking for?
Morten Handberg: Tip speeds and rain intensity.
Uh, obviously droplet size have an impact, but. But what is an operator you can actually see and monitor for is, well, you know, your tip speed of the blade that matters. Uh, but it is really the rain intensity. So if you have [00:04:00] sort of a, an average drizzle over the year, that’s a much better condition than if you have like, you know, showers in, in, in, in a, in a few hour sessions at certain points of time.
Because then, then it becomes an aggressive erosion. It’s not, it’s, you don’t, you get much higher up on the. On the, on the fatigue curve, uh, then if it’s just an average baseline load over long periods of time,
Allen Hall: yeah, that fatigue curve really does matter. And today we’re looking at what generally is called VN curves, velocity versus number of impacts, and.
The rain erosion facilities I’ve seen, I’ve been able to, to give some parameters to, uh, provide a baseline or a comparison between different kinds of coatings. Is is that the, the standard as everybody sees it today, the sort of the VN curve
Morten Handberg: that is what’s been developed by this scientific, uh, community, these VN curve, that that gives you some level of measure.
I would still say, you know, from what we can do in a rain erosion tester to what is then actually going on [00:05:00] the field is still very two very, very, very different things you can say. If you can survive a thousand hours in a rain erosion tester, then it’s the similar in the field that doesn’t really work like that.
But there are comparisons so you can do, you know, uh, a relationship study, uh, between them. And you can use the VN curves to determine the ERO erosion aggressiveness. Field. We did that in the bait defect forecasting that we did in wind pile up with DCU back in 2019, uh, where we actually looked at rain erosion across Europe.
Uh, and then the, uh, the actual erosion propagation that we saw within these different sites, both for offshore and for onshore, where we actually mapped out, um, across Europe, you know, which areas will be the most erosion prone. And then utilize that to, to then mo then, then to determine what would be the red, the best maintenance strategy and also, uh, erosion, uh, LEP, uh, solution for that wind farm.
Allen Hall: Oh, okay. Uh, is it raindrop size then, or just [00:06:00] quantity of raindrops? Obviously drizzle has smaller impact. There’s less mass there, but larger raindrops, more frequent rain.
Morten Handberg: If you have showers, it tends to be larger drops. Right. So, so they kind of follow each other. And if it’s more of a drizzle. It will be smaller raindrops.
They typically follow each other. You know, if you’ve been outside in a rainstorm before we just showered, you would have sense that these are, these are much higher, you know, raindrop sizes. So, so there is typically an a relation between raindrop size and then showers versus a drizzle. It’s typically more fine, fine grain rain drops.
Allen Hall: And what impact does dirt and debris mixed in with the rain, uh, affect leading edge erosion? I know a lot of, there’s a lot of concern. And farm fields and places where there’s a lot of plowing and turnover of the dirt that it, it, it does seem like there’s more leading edge erosion and I, I think there’s a little bit of an unknown about it, uh, just because they see leading edge [00:07:00]erosion close to these areas where there’s a lot of tilling going on.
Is it just dirt impact worth a blade or is it a combination of dirt plus rain and, and those two come combining together to make a worse case. Uh, damage scenario.
Morten Handberg: Technically it would be slightly worse than if it were, if there is some soil or, or sand, or sand contamination in the raindrops. But I mean, logically rain typically, you know, comes down from the sky.
It doesn’t, you know, it doesn’t mix in with the dirt then, you know, it would be more if you have dirt on the blades. It’s typically during a dry season where it would get mixed up and then blown onto the blades. Honestly, I don’t think that that is really what’s having an impact, because having contamination in the blade is not something that is, that would drive erosion.
I think that that is, I think that is, that is a misunderstanding. We do see sand, sand erosion in some part of the world where you have massive, uh, sand, uh, how do you say, sandstorms [00:08:00] coming through and, and that actually creates an, an abrasive wear on the plate. It looks different from rain erosion because it’s two different mechanisms.
Uh, where the sand is actually like a sandpaper just blowing across the surface, so you can see that. Whereas rain is more of this fatigue effect. So I think in the, theoretically if you had soil mixed in with rain, yes that could have an impact because you would have an a, a hardened particle. But I do, I don’t think it’s what’s driving erosion, to be honest.
Allen Hall: Okay, so then there’s really two different kinds of failure modes. A particle erosion, which is more of an abrasive erosion, which I would assume be a maybe a little wider, spread along the leading edge of the blade versus a fatigue impact from a raindrop collision. They just look different, right?
Morten Handberg: Yeah, so, so sand erosion you could have spreading across a larger surface of the blade because it, because it doesn’t bounce off in the same way that a raindrop would, you know, because that’s more of an impact angle and the load that it’s applying.
So if it comes in at a, at a st [00:09:00] at a, um, at the, at the, at a, at a steep angle, then it would just bounce off because the amount of load that it’s impacting on would be very limited. So that’s also why we don’t really see it on the, um, uh, outside of the leading edge. Whereas sand erosion would have a, would, would have a different effect because even at a steep angle, it would still, you know, create some kind of wear because of the hardened particle and the effect of that.
Allen Hall: Okay. So let’s talk about incubation period, because I’ve seen a lot of literature. Talking about incubation period and, and what that means. What does incubation period mean on a leading edge coating?
Morten Handberg: So that is, that, that is from when you start having the first impacts until you get the, the, the change in structure.
So when you get to the mass loss or first pitting, that would be your incubation period, because that is from when it starts until you can see the actual effects. Would say that, that that is what would be defined as the incubation period of leading into erosion.
Allen Hall: Okay. So you wanna then maximize the incubation period where the coating still looks mostly pristine [00:10:00] once incubation period is over and you get into the coating.
Are there different rates at which the coatings will deteriorate, or are they all pretty much deteriorating at roughly the same rate?
Morten Handberg: I mean, for the really high durability. We don’t really have good enough data to say anything about whether the, um, the, the period after the incubation period, whether that would actually, how that would work in the field.
We don’t really know that yet. I would say, because the, um, some of the, the shell solutions, some of the high end polyurethane coatings, if they fail, typically it’s because of workmanship. Or adhesion issues. It’s has so far not really been tied in directly in, into leading edge erosion. Uh, the ones that I’ve seen, so typically, and, and, you know, all of these high-end coatings, they’re just, they, they have shown, you know, some of them you couldn’t even wear down in a rain erosion tester.
Um, so, so we don’t really know. Um, how, [00:11:00] how the, how the shells, they would, they, they, they, they, how they would react over the five, 10 year period because we haven’t seen that much yet. And what we have seen have been more of a mechanical failure in, in the bonding
Allen Hall: that, I guess that makes sense. Then operators are still buying wind turbine blades without any leading edge coating at all.
It is basically a painted piece of fiberglass structure. Is that still advisable today or are there places where you could just get away with that? Or is that just not reality because of the tip speeds?
Morten Handberg: For the larger, I would say anything beyond two megawatt turbines, you should have leading edge protection because you’re at tip speeds where, you know, any kind of rain would create erosion within, um, within the lifetime of the late.
That is just a fact. Um, so. I don’t, I don’t see any real areas of the world where that would not apply. And if it, if you are in a place where it’s really dry, then it would typically also mean that then you would have sand erosion. Is that, that, [00:12:00] that would, I would expect that it would be one of the two.
You wouldn’t be in an area where it couldn’t get any kind of erosion to the blades. Um, so either you should have either a very tough gel code, um, coating, or you should have have an LEP per urethane based coating. On the blades,
Allen Hall: well do the manufacturers provide data on the leading edge offerings, on the coatings, or even the harder plastic shells or shields.
Does, is there any information? If I’m an operator and I’m buying a a three megawatt turbine that comes along with the blade that says, this is the li, this is the estimated lifetime, is that a thing right now? Or is it just We’re putting on a coating and we are hoping for the best?
Morten Handberg: The OEMs, as far as I, I haven’t seen any.
Any contract or agreement where today, where erosion is not considered a wear and tear issue, there is simply no, no coverage for it. So if you buy a turbine and there’s any kind of leading [00:13:00] edge erosion outside of the end of warranty period, it’s your your problem. There is no guarantee on that.
Allen Hall: So the operator is at risk,
Morten Handberg: well, they’re at risk and if they don’t take matters into their own hands and make decisions on their own.
But they would still be locked in because within the warranty period, they will still be tied to the OEM and the decisions that they make. And if they have a service agreement with the OEM, then they would also be tied in with what the OEM provides.
Allen Hall: So that does place a lot of the burden on the owner operator to understand the effects of rate erosion, particularly at the at a new site if they don’t have any history on it at all.
To then try to identify a, a coating or some sort of protecting device to prevent leading edge erosion. ’cause at the end of the day, it does sound like the operator owner is gonna be responsible for fixing it and keeping the blades, uh, in some aerodynamic shape. That that’s, that’s a big hurdle for a lot of operators.
Morten Handberg: The problem is that if you have a service [00:14:00]contract, but you are depending on the OEM, providing that service. Then you have to be really certain that any leading edge erosion or anywhere on the leading edge is then covered by that contract. Otherwise, you’re in, you’re in a really bad, you’re in a really risky situation because you can’t do anything on your own.
Because if you’re a service contract, but you’re beholden to whatever the, your service provider is, is, is agreeing to providing to you. So you might not get the best service.
Allen Hall: And what are the risks of this? Uh, obviously there can be some structural issues. Particularly around the tips of the blaze, but that’s also power loss.
What are typical power loss numbers?
Morten Handberg: Well, there is a theoretically theoretical power loss to it, but for any modern turbine, the blade, the, the turbine would simply regulate itself out of any leading erosion loss. So, so the blades would just change their behavior that the turbine would just change, its its operation [00:15:00]conditions so that it would achieve the same lift to the blade.
So. Uh, any study that we have done or been a part of, uh, even, you know, comparing blades that were repaired, blades that were cleaned, blades that were, uh, left eroded, and then operating the, uh, the deviation was within half, half percent and that was within the margin of error. We couldn’t read, we couldn’t see it even for really, you know, really er road blades.
Of course there is different between turbines. Some turbines, they, they could show it, but I haven’t seen any data that suggests that erosion actually leads to a lot of power loss. There is a theoretical loss because there is a loss in aerodynamic performance, but because blades today they’re pitch controlled, then you can, you can regulate yourself out of that.
Some of that, uh, power laws,
Allen Hall: so the control laws in the turbine. Would know what the wind speeds are and what their power output should be, and it’ll adjust the [00:16:00]pitch of each of the blades sort of independently to, to drive the power output.
Morten Handberg: Typically, erosion is a uniform issue, so what happens on one blade happens on three.
So it’s rare to see that one blade is just completely erod in the two other they look fine. That’s really rare unless you start, you know, doing uh, abnormal repairs on them. Then you might get something. But even then, I mean, we’re not talking, you know, 10 per 10 degrees in, in variation. You know, it’s not, it’s not anything like that.
It’s very small changes. And if they would do a lot of weird DA, you know, uh, different angles, you would get instant imbalance and then, you know, you would get scatter alarm. So, so you would see that quite fast.
Allen Hall: Well, let me, let me just understand this just a little bit. So what the control logs would do would increase the pitch angle of the blaze, be a little more aggressive.
On power production to bring the power production up. If leading edge erosion was knocking it down a percentage point or two, does that have a consequence? Are like when you [00:17:00] start pitching the blades at slightly different angles, does that increase the area where rain erosion will occur? Is like, are you just.
Keep chasing this dragon by doing that,
Morten Handberg: you could change the area a little bit, but it’s not, it’s not something that, that changes the erosion, uh, that the erosion zone, that that much. It’s very minimal. Um, and one, one of the, another, another reason why, why you might see it might, might not see it as much is because voltage generator panels is widely used in the industry today.
And, and Vortex panel, they are. Uh, negating some of the negative effect from, uh, leading erosion. So that also adds to the effect that there, that the aerodynamic effect of leading erosion is limited, uh, compared to what we’ve seen in the past.
Allen Hall: Okay. So there’s a couple manufacturers that do use vortex generators around the tip, around the leading edge erosion areas right outta the factory, and then there’s other OEMs that don’t do that at all.
Is, is there a benefit to [00:18:00] having the VGs. Right out of the factory. Is that, is that just to, uh, as you think about the power output of the generator over time, like, this is gonna gimme a longer time before I have to do anything. Is, is in terms of repair,
Morten Handberg: it does help you if you have contamination of the blade.
It does help you if you have surface defects off the blade. That, that any, uh, any change to the air, to the aerodynamics is, is reduced and that’s really important if you have an optimized blade. Then the negative effect of leading erosion might get, uh, you know, might, might, might get, might get affected.
But there are, there are still reasons why I do want to do leading erosion repairs. You should do that anyway, even if you can’t see it on your power curve or not, because if you wait too long, you’ll start to get structural damages to the blade. As we talked about last time. It’s not that leading edge erosion will turn into a critical damage right away, but if you need, if you go into structural erosion, then the, then the cost of damage.
The cost of repairing the damage will multiply. Uh, [00:19:00] and at, at a certain point, you know, you will get a re structure. It might not make the blade, you know, uh, cost a, a condition where the blade could collapse or you’re at risk, but you do get a weakened blade that is then susceptible to damage from other sources.
Like if you have a lighting strike damage or you have a heavy storm or something like that, then that can accelerate the damage, turning it into a critical damage. So you should still keep your leading edge in, in shape. If you want to do to, to minimize your cost, you should still repair it before it becomes structural.
Allen Hall: Okay. So the blades I have seen where they actually have holes in the leading edge, that’s a big problem just because of contamination and water ingress and yeah, lightning obviously be another one. So that should be repaired immediately. Is is that the, do we treat it like a cat four or cat five when that happens?
Or how, what? How are we thinking about that?
Morten Handberg: Maximum cat, cat four, even, even in those circumstances because it is a, it is a severe issue, but it’s not critical on, on its own. So I would not treat it as a cat five where you need to stop [00:20:00] the turbine, stuff like that. Of course, you do want, you don’t want to say, okay, let’s wait on, let’s wait for a year or so before we repair it.
You know, do plan, you know, with some urgency to get it fixed, but it’s not something where you need to, you know, stubble works and then get that done. You know, the blade can survive it for, for a period of time, but you’re just. Susceptible to other risks, I would say.
Allen Hall: Alright. So in in today’s world, there’s a lot of options, uh, to select from in terms of leading edge protection.
What are some of the leading candidates? What, what are some of the things that are actually working out in the field?
Morten Handberg: What we typically do, uh, when we’re looking at leading edge erosion, we’re looking at the, the raw data from the wind farm. Seeing how, how bad is it and how long have the wind farm been operated without being repaired?
So we get a sense of the aggressiveness of the erosion and. Um, if we have reliable weather data, we can also do some modeling to see, okay, what is the, what is the, the, uh, environmental conditions? Also, just to get a sense, is this [00:21:00] material driven fatigue or is it actually rain erosion driven fatigue?
Because if the, if the coating quality was not, was not very good, if the former lead leading edge, it was not applied very, very, very good, then, you know, you still get erosion really fast. You get surface defects that, uh, that trigger erosion. So that’s very important to, to, to have a look at. But then when we’ve established that, then we look at, okay, where do we have the, the, the, uh, the structural erosion zone?
So that means in what, in what part of the BA would you be at risk of getting structural damage? That’s the part where that you want to protect at all costs. And in that, I would look at either shell solution or high duty, um, put urethane coating something that has a a long durability. But then you also need to look at, depending on whether you want to go for coating or shell, you need to look at what is your environmental condition, what is your, you know, yeah.
Your environmental conditions, because you also wanna apply it without it falling off again. Uh, and if you have issues with [00:22:00] high humidity, high temperatures, uh, then a lot of the coatings will be really difficult to process or, you know, to, to. Uh, to handle in the field. And, you know, and if you don’t, if you don’t get that right, then you just might end up with a lot of peeling coating or uh, peeling shells.
Um, so it’s very important to understand what is your environmental conditions that you’re trying to do repairs in. And that’s also why we try not to recommend, uh, these shell repairs over the entire, out a third of the blade. Because you’re, you’re just putting up a lot of risk for, for, uh, for detaching blades if you put on too high, um, uh, how do you say, high height, sea of solutions.
Allen Hall: Yeah. So I, I guess it does matter how much of the blade you’re gonna cover. Is there a general rule of thumb? Like are we covering the outer 10%, outer 20%? What is the. What is that rule of thumb?
Morten Handberg: Typically, you know, you, you get a long way by somewhere between the outer four to six meters. Um, so that would [00:23:00]probably equivalate to the, out of the outer third.
That would likely be something between the outer 10 to 15 to 20% at max. Um, but, but it is, I, I mean, instead of looking at a percentage, I usually look at, okay, what can we see from the data? What does that tell us? And we can see that from the progression of the erosion. Because you can clearly see if you have turbines that’s been operating, what part of the blade has already, you know, exposed laminate.
And where do you only have a light abrasion where you only have a light abrasion, you can just continue with, and with the, with, with the general coating, you don’t need to go for any high tier solutions. And that’s also just to avoid applying, applying something that is difficult to process because it will just end up, that it falls off and then you’re worse off than, than before actually.
Allen Hall: Right. It’s about mitigating risk at some level. On a repair,
Morten Handberg: reducing repair cost. Um, so, so if you, if you look at your, your conditions of your blades and then select a solution that is, that is right for that part of [00:24:00] the blade
Allen Hall: is the best way to repair a blade up tower or down tower is what is the easiest, I guess what’s easier, I know I’ve heard conflicting reports about it.
A lot of people today, operators today are saying we can do it up tower. It’s, it’s pretty good that way. Then I hear other operators say, no, no, no, no, no. The quality is much better if the blade is down on the ground. What’s the recommendation there?
Morten Handberg: In general, it can be done up tower. Um, it is correct if you do a down tower, the quality is better, but that, that, that means you need to have a crane on standby to swap out blades.
Uh, and you should have a spare set of blades that you can swap with. Maybe that can work. Um. But I would say in general, the, your, your, your, your cheaper solution and your more, you know, you know, uh, would be to do up tower. And if, and again, if you do your, your, your homework right and, and selecting the right, uh, products for, for your [00:25:00] local environments, then you can do up tower then leading it, erosion.
Not something that you need to, you should not need to consider during a down tower. Unless you are offshore in an environment where you only have, uh, 10 repair days per year, then you might want to look at something else. But again, if we talk for offs for onshore, I would, I would always go for up, up tower.
I, I don’t, I don’t really see the need for, for, for taking the blades down.
Allen Hall: So what is the optimum point in a blaze life where a leading edge coating should be applied? Like, do you let it get to the point where you’re doing structural repairs or. When you start to see that first little bit of chipping, do you start taking care of it then there I, there’s gotta be a sweet spot somewhere in the middle there.
Where is that?
Morten Handberg: There is sweet spot. So the sweet spot is as soon as you have exposed laminate, because from exposed laminate, uh, the repair cost is exactly the same as if it was just, you know, uh, a light abrasion of the coating because the, the, the time to, to, um, prepare the [00:26:00] surface to apply the coating is exactly the same.
From, you know, from, from, from light surface damage to exposed laminate. That is the same, that is the same repair cost. But as soon as you have a structural damage to your blade, then you have to do a structural repair first, and then you’re, you’re multiplying the repair time and your repair cost. So that is the right point in time.
The way to, to determine when that is, is to do inspections, annual inspections, if you do 10% of your wind farm per year. Then you would know why, what, how the rest of your wind farm looks like because erosion is very uniform across the wind farm. Maybe there are some small deviations, but if you do a subset, uh, then, then you would have a good basic understanding about what erosion is.
You don’t need to do a full sweep of the, of the wind farm to know, okay, now is my right time to do repairs.
Allen Hall: Okay, so you’re gonna have a, a couple years notice then if you’re doing drone inspections. Hopefully you put, as you put your blades up, doing a drone inspection maybe on the ground so you [00:27:00] have a idea of what you have, and then year one, year two, year three, you’re tracking that progression across at least a sampling of the wind farm.
And then, then you can almost project out then like year five, I need to be doing something and I need to be putting it into my budget.
Morten Handberg: When you start to see the first minor areas of exposed laminate. Then the year after, typically then you would have a larger swat of, of laminated exposure, still not as structural.
So when you start to see that, then I would say, okay, next year for next year’s budget, we should really do repairs. It’s difficult when you just direct the wind farm, maybe have the first year of inspection. It’s difficult to get any, any kind of, you know, real sense of what is the, you know, what is the where of scale that we have.
You can be off by a factor of two or three if, you know, if, um, so I would, I would give it a few years and then, uh, then, then, then see how things progresses before starting to make, uh, plans for repairs. If you [00:28:00] don’t have any leading edge erosion protection installed from the start. I would say plan, at least for year, year five, you should expect that you need to go out, do and do a repair.
Again, I don’t have a crystal ball for every, you know, that’s good enough to predict for every wind farm in the world, but that would be a good starting point. Maybe it’s year three, maybe it’s year seven, depending on your local conditions. That is, but then at least you know that you need to do something.
Allen Hall: Well, there’s been a number of robotic, uh, applications of rain erosion coatings. Over the last two, three years. So now you see several different, uh, repair companies offering that. What does the robotic approach have to its advantage versus technicians on ropes?
Morten Handberg: Obviously robots, they don’t, they don’t, uh, get affected by how good the morning coffee was, what the latest conversation with the wife was, or how many hours of sleep it got.
There is something to, with the grown operator, uh, you know how good they are. But it’s more about how well, uh, [00:29:00] adjusted the, the controls of the, of the, the robot or the drone is in its application. So in principle, the drone should be a lot better, uh, because you can, it will do it the right, the same way every single time.
What it should at least. So in, so in principle, if you, you, you, when we get there, then the leading it then, then the robot should be, should outmatch any repair technician in, in the world. Because repair technician, they’re really good. They’re exceptionally good at what they do. The, the, the far majority of them, but they’re, they’re still people.
So they, you know, anyone, you know, maybe standing is not a hundred percent each time, maybe mixing of. Um, of materials and they’re much better at it than I am. So no question there. But again, that’s just real reality. So I would say that the, the, the draw, the robots, they should, uh, they should get to a point at some, at some point to that they will, they will be the preferable choice, especially for this kind of, this kind of repair.
Allen Hall: What should [00:30:00] operators be budgeting to apply a coating? Say they’re, you know, they got a new wind farm. It’s just getting started. They’re gonna be five years out before they’re gonna do something, but they, they probably need to start budgeting it now and, and have a scope on it. ’cause it’s gonna be a capital campaign probably.
How much per turbine should they be setting aside?
Morten Handberg: I would just, as a baseline, at least set aside 20,000 per per blade
Allen Hall: dollars or a Corona
Morten Handberg: dollars.
Allen Hall: Really. Okay.
Morten Handberg: Assuming that you actually need to do a repair campaign, I would say you’re probably ending up in that region again. I can be wrong with by a factor of, you know, uh, by several factors.
Uh, but, um, but I would say that as a starting point, we don’t know anything else. I would just say, okay, this should be the, the, the, the budget I would go for, maybe it’ll be only 10 because we have a lesser campaign. Maybe it will be twice because we have severe damages. So we need just to, to, to source a, um, a high end, uh, LEP solution.
Um, so, so [00:31:00] again, that would just be my starting point, Alan. It’s not something that I can say with accuracy that will go for every single plate, but it would be a good starting point.
Allen Hall: Well, you need to have a number and you need to be, get in the budget ahead of time. And so it, it’s a lot easier to do upfront than waiting till the last minute always.
Uh, and it is the future of leading edge erosion and protection products. Is it changing? Do you see, uh, the industry? Winning this battle against erosion.
Morten Handberg: I see it winning it because we do have the technology, we do have the solutions. So I would say it’s compared to when we started looking at it in 14, where, you know, we had a lot of erosion issues, it seems a lot more manageable.
Now, of course, if you’re a, if you’re a new owner, you just bought a wind farm and you’re seeing this for this first time, it might not be as manageable. But as an, as an industry, I would say we’re quite far. In understanding erosion, what, how it develops and what kind of solutions that that can actually, uh, withstand it.
We’re still not there in [00:32:00] terms of, uh, quality in, in repairs, but that’s, um, but, but, uh, I, I think technology wise, we are, we are in a really good, good place.
Allen Hall: All the work that has been done by DTU and RD test systems for creating a rain erosion test. Facility and there’s several of those, more than a dozen spread around the world at this point.
Those are really making a huge impact on how quickly the problem is being solved. Right? Because you’re just bringing together the, the, the brain power of the industry to work on this problem.
Morten Handberg: They have the annual erosion Symposium and that has been really a driving force and also really put DTU on the map in terms of, uh, leading edge erosion, understanding that, and they’re also trying to tie, tie it in with lightning, uh, because, uh.
If you have a ro, if you have erosion, that changes your aerodynamics. That in fact changes how your LPS system works. So, so there is also some, some risks in that, uh, that is worth considering when, when, when discussing [00:33:00]repairs. But I think these of you, they’ve done a tremendous amount of work and r and d system have done a lot of good work in terms of standardizing the way that we do rain erosion testing, whether or not we can then say with a hundred uncertainty that this, uh, this test will then match with.
With, um, how say local environment conditions, that’s fine, but we can at least test a DP systems on, on the same scale and then use that to, to, to look at, well how, how good would they then ferry in in the, um, out out in the real world.
Allen Hall: Yeah, there’s a lot too leading edge erosion and there’s more to come and everybody needs to be paying attention to it.
’cause it, it is gonna be a cost during the lifetime of your wind turbines and you just need to be prepared for it. Mor how do people get ahold of you to learn more about leading edge erosion and, and some of the approaches to, to control it?
Morten Handberg: Well, you can always re reach me, uh, on my email, meh, at wind power.com or on my LinkedIn, uh, page and I would strongly advise, you know, reach out if you have any concerns regarding erosion or you need support with, um, [00:34:00] uh, with blade maintenance strategies, uh, we can definitely help you out with that.
Or any blade related topic that you might be concerned about for your old local wind farm.
Allen Hall: Yes. If you have any blade questions or leading edge erosion questions, reach out to Morton. He’s easy to get ahold of. Thank you so much for being back on the podcast. We love having you. It
Morten Handberg: was fantastic being here.
Cheers. A.
Renewable Energy
Who Decides What is Good and Bad?
Is this really a problem? We can all agree that adequate food and housing are good things, and that hunger and homelessness are bad.
-
Climate Change6 months ago
Guest post: Why China is still building new coal – and when it might stop
-
Greenhouse Gases6 months ago
Guest post: Why China is still building new coal – and when it might stop
-
Climate Change2 years ago
Bill Discounting Climate Change in Florida’s Energy Policy Awaits DeSantis’ Approval
-
Greenhouse Gases2 years ago嘉宾来稿:满足中国增长的用电需求 光伏加储能“比新建煤电更实惠”
-
Climate Change2 years ago
Spanish-language misinformation on renewable energy spreads online, report shows
-
Climate Change2 years ago嘉宾来稿:满足中国增长的用电需求 光伏加储能“比新建煤电更实惠”
-
Climate Change Videos2 years ago
The toxic gas flares fuelling Nigeria’s climate change – BBC News
-
Renewable Energy2 years ago
GAF Energy Completes Construction of Second Manufacturing Facility
