Weather Guard Lightning Tech

The Lightning Diverter Problem with GE Vernova Blades
A design that causes massive problems
As wind turbine operators continue to expand their fleets worldwide with larger turbines, bigger generators, and longer blades, the risk of significant lightning damage continues to plague the industry. Lightning is now the leading cause of unplanned turbine downtime for many operators. In years past, OEM warranties or insurance would cover the costs of repairs and business interruption. Those days are gone. OEMs have eliminated lightning damage from warranties and insurance companies are dramatically raising rates, or eliminating coverage, for lightning damage. That leaves operators exposed to millions in repair bills every year.
The SafeReceptor ILPS System
The basic lightning protection systems for LM Wind Power blades has been two small, coin-sized receptors placed on either side of the blade tip. Designated as the SafeReceptor ILPS, the receptors are connected to an insulated metal cable that runs through the center of the blade which connects to the hub, nacelle, tower and eventually earth. Certified to IEC61400-24, the SafeReceptor ILPS has been used on most onshore LM Wind Power blades since 2011.
LM Wind Power would, occasionally, place a special, additional lightning protection feature onto their blades. Patented in 2005, this lightning add-on contained a line of stainless steel cross-shaped buttons in a soft, gray-colored sealant which formed a segmented lightning diverter. As lightning approached a blade, the LM segmented lightning diverter helped guide the lightning to the receptor, lowering the chance of lightning damage to the blade.
LM Wind Power, and eventually TPI Composites, used the LM Wind Power segmented lightning diverter. Most installations of the LM segmented lightning diverter placed the device behind the receptor – using the receptor to block rain and airflow impact. The reason? If the LM Wind Power diverter was directly exposed to the wind and rain it would eventually degrade.
Remarkably, the LM diverter strip was used sparingly, or not at all, on the LM/TPI 56.9m and 62.2m blades. As it turns out, the 56.9m / 62.2m are unusually vulnerable to lightning damage. In a WGLT study of over 900 GE Vernova onshore turbines in Texas and Oklahoma with blades exceeding 50m, the rate of lightning damage was approximately 1 in 5 strikes. The industry standard for lightning damage is roughly 1 in 50 strikes per the IEC standard. That results highlight a gigantic risk for wind turbine operators.
Presumably in response to these high damage rates, GE Vernova has introduced LPS “improvements” to the 56.9m and 62.2m blades. Two additional receptors have been added to the blade approximately 3m from the blade tip. Also, LM Wind Power diverter strips have been added to every receptor; with short pieces behind the tip receptors plus long pieces behind and in front of the two receptors down the blade.

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

Why are the LM Wind Power diverters not oriented upwards towards the storm clouds? Our research indicates that exposing the broad side of the diverter to rain erosion causes the part to fail.
Several years ago, Weather Guard Lightning Tech developed an accelerated rain erosion test rig to mimic rain erosion that appears on aircraft nose radomes and wind turbine blade tips. This test sprays water droplets onto test samples at 135 m/s (300 mph) and has yielded accurate predictions for lifetimes. WGLT examined the durability of the LM Wind Power diverters in our accelerated rain erosion test rig. The results were astonishing. The LM Wind Power diverter failed in under 1 minute for every orientation.

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

Sample 2 Post-Test 90 Degrees to Face of Diverter

Sample 5 Post-Test 0 Degrees to Side

Sample 6 Post-Test 0 Degrees to Leading Edge
Now, what does this mean for the lightning protection for your GE Vernova wind turbine blades with LM Wind Power diverters? You need to monitor the diverters for damage and peeling off the blade. Missing metal segments from a diverter or sections of diverter that have separated from the blade need to repaired or replaced.

What’s the risk? Your blades are susceptible to significant lightning damage which could cost you $$$.
For more information about StrikeTape lightning protection technology and installation services, contact Weather Guard Wind at 1.413.217.1139 or info@wglightning.com.
About Weather Guard Wind: Weather Guard Wind specializes in advanced lightning protection solutions for wind energy applications, with installations protecting turbines worldwide in the most challenging lightning environments.
https://weatherguardwind.com/the-lightning-diverter-problem-with-ge-vernova-blades/
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Vineyard Wind Sues GE Vernova, US Monopile Factory Bankrupt
Weather Guard Lightning Tech

Vineyard Wind Sues GE Vernova, US Monopile Factory Bankrupt
Allen covers EEW American Offshore Structures’ Chapter 11 filing, Vineyard Wind suing GE Vernova for $545 million, Europe’s exit from Korea, and wind project wins in Australia and Canada.
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!
There is a story unfolding across this industry right now. It is a story of two worlds. One world is closing its doors. The other is throwing them wide open.
Let us start in New Jersey. EEW American Offshore Structures filed for Chapter Eleven bankruptcy on April eighth. This was the first monopile manufacturing facility ever built in the United States. New Jersey Governor Phil Murphy announced a two hundred fifty million dollar investment in the Paulsboro Marine Terminal back in twenty twenty. It was called the largest industrial offshore wind investment in the country at the time. At full buildout… five hundred thousand square feet of production space. More than one hundred monopiles per year. Five hundred workers. They even built the first American-made monopile… for Orsted’s Ocean Wind project. It weighed three million pounds. It measured three hundred feet long.
Then Orsted canceled Ocean Wind One and Two. Then Shell pulled out of Atlantic Shores. Without contracted work… workers disassembled and recycled finished monopiles for scrap. Federal policy shifts removed the pipeline of future projects. A landlord eviction filing followed. And then… Chapter Eleven. That is a two hundred fifty million dollar facility… with nowhere left to go.
Now stay with us. Because just offshore… another American offshore wind story is fighting for its life. Vineyard Wind… the sixty-two turbine project fifteen miles south of Martha’s Vineyard… filed suit in Massachusetts against GE Renewables. GE Vernova says Vineyard Wind owes it three hundred million dollars for work already performed… and it wants to walk away at the end of April. Vineyard Wind says not so fast.
The developer says GE still owes five hundred forty-five million dollars for what it calls inexcusably poor performance after a catastrophic turbine blade collapse in July of twenty twenty-four. Fiberglass blade fragments washed onto Nantucket beaches during peak tourist season. Sixty-eight of seventy-two blades had to be removed and replaced. That set the project back nearly two years. Construction did reach completion in March… making Vineyard Wind the first offshore project to finish under the current administration. But now the only contractor capable of completing the remaining work… wants out. A court hearing was scheduled for Thursday.
And now… look eastward. Something similar is playing out in Korea. European offshore wind companies are exiting the Korean market one by one. Corio Generation, a British firm owned by Macquarie, disbanded its Korean unit and pulled out of joint projects in Busan and Ulsan. Germany’s RWE quit offshore wind projects in Taean and Sinan counties. Vestas postponed its turbine factory in Mokpo… indefinitely. Equinor began reducing its Korean workforce. Shell exited the Korean offshore market entirely in twenty twenty-four.
These companies point to worsening global profitability… and Korean government policies they say favor domestic companies over firms with greater experience. Korea had a target of three gigawatts of offshore wind by twenty thirty. That goal is now in serious doubt.
But here is where the story turns. Not every market is closing its door. Eight thousand miles from New Jersey… in the Sunshine State of Queensland, Australia… the final forty-one turbines just arrived at the Wambo wind project. Cubico Sustainable Investments and Stanwell are building a five hundred six megawatt project on the Darling Downs. Stage One… two hundred fifty-two megawatts… already feeding the Queensland grid. Stage Two deliveries are now complete. Commissioning and full operations are on track for the end of twenty twenty-six.
And up in Ontario, Canada… the province just approved fourteen new wind and solar projects totaling more than thirteen hundred megawatts. The average price… eight point eight cents per kilowatt hour. Compare that to twenty-one point four cents for some proposed nuclear projects… and more than thirty-two cents for certain new reactor designs. Contracts run for twenty years, with all projects online before twenty thirty.
So let us step back. In New Jersey… the first American monopile factory files for bankruptcy. Off Massachusetts… a completed offshore wind farm fights to keep its contractor. In Korea… European developers pack their bags. But in Australia… turbines arrive on schedule. And in Canada… wind power undercuts nuclear at the meter.
The wind energy industry is not in retreat. It is choosing its battlegrounds. And where the conditions are right… the blades are turning.
And now you know… the rest of the story.
That is the state of the wind industry for the 13th of April, twenty twenty-six. Join us for the Uptime Wind Energy Podcast tomorrow.
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