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TPI Files Bankruptcy, Ørsted Fundraising Round

The crew discusses TPI Composites’ chapter 11 bankruptcy filing and Ørsted’s $9 billion fundraising amid financial challenges. Joel gives an update about the 2026 Melbourne Wind O&M 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 back to the Uptime Wind Energy Podcast, Joel Saxon.

Is in Australia. You want to tell everybody where you’re at at the moment?

Joel Saxum: Yeah, we’re down in Melbourne. I’m here with Matthew Stead from Ping as well. Uh, Rosemary was supposed to join us, but uh, of course she’s under the weather. Uh, but we are down here doing basically a, a tour to Melbourne, uh, I guess you could say, of the wind industry.

So if you don’t know in Australia, a lot of the wind operators, uh, and ISPs, uh, and OEMs, to be honest with you. Are located here in Melbourne, uh, and we are talking to them all about the conference that we’re gonna put on this February. Uh, it is a, the, the new and improved version of the, [00:01:00] uh, successful one we did last year.

So we’re taking the feedback that we got right after the event last year, uh, connecting with these, uh, all the stakeholders down here and seeing what do they, what do they want to hear for the next one? What did we do well? What could be better? Uh, we’re looking at venues, we’re doing kind of all the above to get this, uh.

Conference up and running, and I know, uh, Matthew and I, I think we’ve had four to five meetings a day, every day. Um, thank you to the people that we’ve met with, if you’re listening, because it’s been really good for us, uh, very engaging, lots of feedback. So I think we’ve got a, we’ve got a good list of speakers lined up and then also, um, content for next year.

That’s great. So what we’re looking at right now as well, uh, if you’re inking this on your calendar. For the, uh, wind energy o and m 2026 conference here in Melbourne is February 17th and 18th. This year we’re gonna do two full days of, uh, panel discussions, round tables, and all kinds of information sharing.

[00:02:00] Uh, the goal, of course, just like last year, gather up some of the smartest people in wind and share strategies that you can take back, uh, for operations and maintenance and, and action within your company.

Allen Hall: And Phil Tarro of Intel stores out in California. And Phil, this has to be one of the. Busiest weeks in wind on the investor side.

So much happening. Osted, uh, is going to issue a $9 billion emergency fundraising round. And I want you to frame this a little bit. I, I, I’ve heard so much on the news and been reading a lot about this, but there’s several undertones, several things happening at the same time and there really hasn’t been a clear path as to why.

Osted has decided to go forward on this fundraising round?

Phil Totaro: Well, effectively it stems from two big things. One is obviously they had shown some financial losses, uh, recently, and this is going back a couple of [00:03:00] years now that had necessitated. You know, companies like EOR coming in and taking a 10% stake, um, just to bolster them again, we, we talked on the show before about the fact that they’re not necessarily wanting to take over, although now there’s some people in, you know, Denmark, that are kind of pushing the Danish government to sell off their chunk.

And the presumption is that it would be sold to, to somebody like eor. So we’ll still see if that’s possible or even. You know, uh, likely to happen, but there’s a project here in the United States called Sunrise Wind, which Ted was hoping to sell off a chunk of to a co-investor and. Because of some of the rule changes around, um, tax credit qualification, they’re probably not going to be able to move forward in the way that they had hoped to, um, with that stake sale.

And as a result, [00:04:00] it’s leading them to absorb a lot of the, um. You know, financial losses from, you know, some of the delays and, and other issues that they’ve had with getting a lot of these offshore projects, you know, uh, up and running. Uh, it’s, it’s kind of forcing them to do this capital raise to be able to provide themselves with enough cash to be able to continue operating.

The

Allen Hall: Sunrise Wind Project was a partnership between Orit and Eversource, and Eversource pulled out of that roughly a year ago. And the other one, which had a partner that, uh, Ted had who pulled out was for Ocean Wind one and two, which was PSEG, which is a New Jersey power company. Eversource being a northeastern power company, essentially those two pulled out like in 2023 and 2024 when the price of steel went up, inflation was high, the cost of the projects went up.

So they’ve been out for a little while still. [00:05:00] It was in that interim that Osted just wasn’t able to find anybody to join in on those projects. And it does seem strange, and again, I want to get to this point. All the US investment and offshore, all the US companies are all out. Basically you have EOR and you have Osted Dominion.

Dominion. Okay, that’s true. But Di Dominion is sort of a different animal.

Phil Totaro: The the reality is, yes, is the short answer to your question, Ellen, that they, they had tried to find another co-investor after, um, Eversource pulled out. The challenge with that was that there. Has has also been, um, an effort by the project developers to try and renegotiate the PPA prices.

Eversource was gonna be one of the main off takers for this. They don’t wanna have to absorb a significantly higher price. And then have to find ways of passing [00:06:00] that on to to customers. And it’s also what led to this challenge of sted not being able to find a new co-investor after Eversource pulled out.

Um, you know, with interest rates being so high. And not being able to renegotiate the PPA anymore. Y you know, the developers that are still, you know, have their lease areas and, and are pursuing their projects. They’re locked in to whatever they’ve got at this point. If nobody else wants to come on board, then it’s up to Ted to basically eat the entire cost of this thing and thus, you know, a major contributor to the capital raise.

Allen Hall: So the discussion online is that the Trump. Administration sort of forced this to happen. That isn’t necessarily correct. I think a lot of this has started a year or two ago. You remember also. Phil with Ocean Wind one and two, the exit fees with the state of New Jersey. I think that Osted was [00:07:00]going to have to pay somewhere around $300 million to the state of New Jersey, and I think they ended up paying less than half of that at the end.

But it’s still a lot of money. There’s a lot of money in exit fees that Osted has paid over the last two years roughly, or, or buybacks. They, they paid Eversource to get

Phil Totaro: out. Essentially just to also clarify, you know, what, what the administration’s done has not helped. I think we can all agree on that. The, but the reality of it is that yes, they, they were already in a bad situation that got made even worse by.

Increasing the risk of, you know, particularly a foreign investor coming in and, and being a co-investor in, in this project. Obviously there are any number of utility companies in the United States that could have, you know, uh. Co-invested in, in this project along with Sted. They chose not to because they don’t like the economics of offshore wind.[00:08:00]

Uh, and that’s just the, the reality at this point in time. Uh, I mean, duke Energy this week, or I guess last week as, as this episode airs also just announced that they’re gonna cancel their two North Carolina projects because of the same thing. It’s, it’s basically down to the economics of the project.

And at the end of the day. If you’ve got somebody in the administration that’s making, you know the, the investment environment look even worse than what it already was before he even came into office, then it’s going to necessarily, you know, take more options off the table for. Potential investors that could have come in and at least helped, uh, kind of share the, the risk and, and, you know, reduce the amount of, of capital outlay that OSTED would’ve had to make just by themselves.

In my

Joel Saxum: mind, with this new kind of like P-T-C-I-T-C cliff coming, there’s no [00:09:00] reality where, uh, capital gets cheap enough, interest rates get low enough in time for any of that to change like that, that’s just not gonna happen. We’ve got 18 months and we need to, it would have to come down by percentage points, not basis points.

And I don’t think that’s going to, there’s no reality of that happening. I think

Allen Hall: that’s true, generally speaking. Right? But I think the problem is, is where are the New York’s and the Massachusetts of the world gonna be able to get power from? They need this, they really do need offshore wind. The prices of electricity there, uh, if you’re a consumer, is about $300 a megawatt hour.

That’s what I was paying in Massachusetts to buy power on the grid. So $150 a megawatt hour coming off of the, uh, you know, offshore wind farm. Yeah, wholesale still is, is high compared to other parts of the United [00:10:00]States, but as it’s half of what I was paying as the consumer. So there

Phil Totaro: is, uh, a dichotomy there, right?

Yes. But keep in mind, that’s only for the generation cost. So where, where I am in California, I pay basically $380 a megawatt hour for electricity as a consumer. Now half of that. Is generation. The other half is, uh, split between the transmission and distribution cost plus the overhead to Southern California Edison as the utility.

The reality is that yes, the, the generation cost may be 150 bucks, but they’re still gonna have to raise prices for consumers to be able to sell them the power because you have to factor in the transmission and generation cost, and they’re gonna wanna maintain at least a 20% overhead on all that. And because that’s literally their profit margin.

Allen Hall: Well, Phil, what I’m trying to get at is the other half of the equation, the [00:11:00] transmission distribution piece is not cheap. So we, we force all the, the generation side to be as low as possible, but the people in the middle, it’s the middlemen, as they would call it, are taking a substantial amount of the money that you’re paying for electricity today.

So yes, offshore wind is expensive. So is transmission and distribution. And you would think something has been around for 30, 40, 50 years, transmission and distribution, most of it in the United States has been around at least that long. You think that the cost of that would come down over time and it really hasn’t.

Uh, which the economics doesn’t make any sense about that. So when it’s, when we’re talking about Ted, like, yeah, yeah, yeah, all this is not great for Ted, but there is something wrong with the system

Phil Totaro: where Ted can’t make this work. Which is also why we probably shouldn’t have the government canceling transmission projects because we need them and taking, you know, 700 million plus [00:12:00] dollars out of the, um, you know, department of Energy’s grant budget for transmission projects.

I mean, this is a time when we need a lot of that technology, but because it has any association with wind and solar, it’s getting pulled. So, uh, you know, uh, that’s a, that’s a decision that’s been made by the DOE

Joel Saxum: Phil and I, and I back this one up. I saw this just, uh, yesterday. I think there was like a, a double digits coal projects pushed forward.

I don’t know if you saw that. There was like a, there was a pre, there was a press release where there was like something like 11 coal projects or something like approved to move forward and it’s like. This is, this is yesterday. This is yesterday’s technology. We’re moving forward. Why are we pushing coal?

And there was a guy on Fox News talking about it, and he was saying. They were saying like, well, have you made strides for coal to be cleaner? Because of course you have. And he was like, no, there’s always gonna be a footprint. [00:13:00] Like there was no, there was no like, yeah, we’ve done this clean coal thing. He’s like, ’cause Trump deal talked about it as clean coal.

And uh, they were like, well, you know, it’s coal. There’s always gonna be a footprint with mining. So

Allen Hall: yeah, that’s our re that’s our reality. Are we still gonna dig rocks and then burn them? Is that the plan? Because it does seem a little bit easier to take the wind and turn it directly into electricity.

Same for solar. Turn the sun into electricity without having people digging rocks and moving rocks and transporting rocks and trails to rain and fires and the whole bit. It’s insane

Phil Totaro: right now. Well, for those that also don’t understand wind and solar, by the way, contribute $3.5 billion annually to. Lease payments to landowners directly and to state and federal tax coffers.

So, you know, you, you wanna explain why that’s not [00:14:00] worth something. I’m, I’m prepared to hear it as an American citizen. You can also explain to me, if you’re the government, why you’re canceling lease auctions at Boem, that would’ve generated $1.8 billion for the federal government. That’s revenue that you’re literally throwing away.

Even if you don’t like wind, you don’t wanna see it. It wasn’t not like it, it’s not like it was gonna get built during, you know, his presidency anyway. Why not at least take the money? And then the project developers can go build it, which by the way, they’re gonna do anyway. They can just go build the projects after you leave office.

So you know what? You can’t paint yourself as being pro-business when you actively turn away money.

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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 [00:15:00] eLog ping.com and take control of your turbine’s health today. So Joel watching the Osted stock price. Once they announced this new stock offering, it plummeted about 30% and plummet is probably a pretty good word.

I’ve used the word cliff to describe the drop off to rosemary the other day. It dropped a ton. It hasn’t. If you, I went back and looked at like the 10 year on Sted stock. It was doing great in like 20 20, 20 21 just after COVID, and it’s come down quite a bit since then. But Sted, as an organization is still making money now, not making money as fast as they were before, but they’re still making money.

What? Does this really mean in terms of the long-term outlook for Ted?

Joel Saxum: Well, I know it’s, it’s got the industry of buzz, right? I think I, I woke up, uh, of course I’m in Australia right now, so the time zone’s a little weird, but I woke up with a large handful of [00:16:00] messages from friends around the world. Did you see Orid stock price?

Did you see, or stock price? Um. I think that, uh, I mean, we’ve kind of, we know the situation we’ve talked about on the podcast a lot about what’s going on in offshore wind and the, you know, the impairments on projects and the difficulty in financing and kind of the headwinds that they’ve been facing or as a whole.

Um, at the end of the day, you can see, because I, this is my take, you know, I’m not an economist, but when I looked at, um, how the stock price fell and then it flattened right off. It was like, well, cliff, and then straight off I was thinking, okay, this is institutionalized money that understands what’s going on here and you lower that price than there’s the stock offering, so there’s a cheaper way to get into, or Ted here.

I don’t think it’s gonna affect the long, long term outlook of the company. Like the immediate stock share pricing dropped like a third. That sucks. Right? But it’ll come back, I think, and if you look at, like what you said, the 2020 on [00:17:00] trend, that trend follows a lot of other pure play wind companies as well.

I mean, I guess I, I, I would, I would consider or set a pure play wind company, even though they’re probably 90%. Because they dabble in some battery stuff and V two X stuff and some hydrogen, whatever, but they’re a wind company. Um, and if you watch the trend of other companies in the same space, like they’ve been getting beat up for the last four or five years, uh, during this COVID play, um, or since then.

So I think that, again, the long term run for them, they’ll, they’ll be healthy. They’ll come outta this, they’ll raise some money, um, make some moves so that, I don’t think it’s gonna be a big issue.

Allen Hall: Phil, same thought. Is it gonna be a big setback for Ted or are they gonna need to. Try to sell off some assets because that’s the talk around the industry is that.

They’re gonna do this fundraising effort, but at the same time, they’re gonna try to offload a couple of projects or things that have value today to improve their long-term forecast.

Phil Totaro: Yes. And I [00:18:00] would concur that that’s likely, but that’s also not to freak anybody out because Yeah, I mean, companies normally do this kind of an what they call an asset rotation.

Up until now, particularly with their offshore portfolio, they’ve owned. Almost a hundred percent of most of their projects and only, it’s only been in the past, like five years that they’ve even been adopting the philosophy of going in and getting, um, investment partners to come along with them. Um, and it’s, it’s also, uh, you know, it’s something.

That, that’s been possible through the capital markets as well. The, the problem for them is that they negotiated poorly probably about three, four years ago on some of these contracts that they worked out, particularly for the power offtake in places like New York or New Jersey, et cetera, that led them to these, um, you know, big.

You know, fees for pulling out of [00:19:00] projects and, and cancellation fees, et cetera, et cetera, that, um. It, you know, left them with a lot of, uh, debt and other kind of cash related liability on their books. So the capital raise is necessary. The, the project, um, you know, asset sales and, and things like that, the asset rotation that they can undertake, that’s also necessary in all likelihood.

My concern for Sted, the bigger concern here is. Whether or not they are really going to. Keep flowing cash into potentially unprofitable ventures.

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With Eco Pitch, you can catch problems early, saving hundreds of thousands of dollars. Field tested on over 3000 blades. It’s proven reliability at your fingertips. Choose Eco Pitch for peace of mind. Contact Onyx Insight today to schedule your demo of Eco Pitch. And experience the future of Blade monitoring TPI composites, which controls about 25% of the global wind blade market, excluding China, of course, uh, has filed for chapter 11 bankruptcy with liabilities somewhere between one and $10 billion that they weren’t very specific in the filing.

Uh, there is a lot of questions about TPI at the minute. They have an order book and they push out like 6,000 blades a year, something around that number. Oaktree capitals come in, it has backed them. [00:21:00] Chapter 11, if you’re not familiar with bankruptcy Methods, chapter 11, it allows you to continue to operate and reorganize and restructure your debt.

Chapter seven and some of the other ones are pretty much an immediate shutdown. So TPI is going to continue making blades or getting some funding. But Joel, this is actually a big hit to the GEs of the world who rely on TPI to produce blades. Is it though, right,

Joel Saxum: because you usually, in chapter 11, you usually have like a tiered, a tiered debt structure too, right?

There’s like, there’s Class A, class B, class C, right? So their debt to A TPI is normally gonna be. Raw materials, uh, logistics, those kind of things. Unless, and I don’t know how they do their business. Right. There may be a case where you’re like, ’cause TPI does a lot of work with ge, right? They may have ge, GE may be doing the logistics on their end, so that might not even be on TPIs side of things.

So it’s like. Building rent, [00:22:00] um, you know, uh, capital assets. So if they have loans out against buildings or some things like that, right. Those are usually class A type things where they get paid off first. It’s a little bit rocky, but they’re, they’re able to continue to work, right. So it’ll be, they’ll, they’ll be some changes, but it, they, it shouldn’t upset the wind industry.

Like it shouldn’t have set the supply chain.

Allen Hall: Well, it does introduce another layer of bureaucracy because once you enter into chapter 11, you can’t. Buy supplies, you can’t sell things as easily. It, it becomes much more transactional. You have to have approvals to, so you can’t start selling off assets behind the scene.

Chapter 11 is a very structured environment that you have to operate in. You don’t want to be there if you can avoid it because it just makes things harder to do. But at the, at the same token, and Phil, maybe this is where part of the problem is, they have plenty of orders. But are they getting paid on time?

Which is my first question. Had they been getting paid when they should be getting paid? [00:23:00] And then second has quality issues, uh, about a year or two ago, sort of stacked up where they’ve had to do warranty claims and spend a bunch of money that they weren’t expecting to. Is that what led to this, uh, eventual chapter 11 filing?

Phil Totaro: Yes, all those did contribute. They also had issues, uh, and unexpected costs associated with their expansion. They had some strikes in Turkey where people wanted more money. Um, you know, there were any number of things that that occurred. But I, I wanna go back to this notion that they have up to $10 billion in liability on.

You know, uh, a company valuation of, what did you say before, Alan? It’s like a few million dollars market cap right now for TPI is $7 million and that’s down from a hundred million a couple months ago. That’s extremely concerning, uh, considering the fact. That a, they have such a wide range, you know, between 1 billion and 10 billion.

And [00:24:00] secondly, that obviously stems from the quality issues that go back a number of years. So, I mean, I remember us talking about it a year or two ago on the show about how they’ve brought, you know, uh, quality experts in and, uh, you know. Manufacturing head chief Technology officer, uh, even the CEO got replaced, uh, at one point because of, um, some of the quality issues that they had and how it was being handled by the previous management.

So presumably this is part of a strategy to, you know, again, restructured the debt certainly, but it. You know, these, the liability issues could still persist. Um, because even though, you know, you’re getting bankruptcy protection in chapter 11, um, nobody’s gonna want to come in and buy the company anyway.

You know, they, if they had entered chapter seven where it was a liquidation, then that’s [00:25:00] a scenario where you could have, you know, I, I wouldn’t necessarily. Necessarily say it would’ve been GE Renova comes in and, and buys them. But, um, it could have even opened up the opportunity for, you know, a foreign company to come in because their factories already have, uh, tax credit qualification.

Um, and so somebody could have stepped in and, and, you know, taking that over, but. This is, uh, uh, just the recognition that, okay, if they’re in chapter 11 and they’re restructuring their debt, it doesn’t mean that the debt goes away. It might get reduced. Um, and hopefully it gets reduced if it’s $10 billion.

Um, but because that’s, I mean, that’s literally almost their entire fleet of blades needs to be, yeah. Would need to be replaced.

Allen Hall: Yeah. And, and Joel, I think this is the real crux of this is. You can’t have a billion dollars in debt and operate a blade factory. [00:26:00] That doesn’t make any sense. Do they eventually clear this out?

What do you think is going to happen to TPI do. They just continue to operate. No one has any interest in it. They just continue to make blades and bring in some revenue and restructure the debt. I, I don’t see this ending

Joel Saxum: ending. Well, chapter 11 sometimes is a gateway drug to. Shutting the doors. Yeah.

That could be happening. And then, and then it’s fire sale because then the lawyers step in and you know, there, there’s oversight there. And someone could pick up the assets or the assets get parted out to try to pay back the debtors or the creditors, sorry. Uh, so you could see other blade companies, you could see some something odd or Sonoma and Aris, or of course, I don’t have the insight into those as much as.

Maybe Phil does, but you could see someone else buying this assets.

Phil Totaro: Yeah, it wouldn’t be Sonoma right [00:27:00] now because of the foreign ownership thing for the tax credit qualification, Joel. Um, but there are, you know, you mentioned one company that, that could be interested and has expressed interest in, you know, getting a, a footprint in the us but there’s also companies, you know, in, uh, other parts of the world that.

You don’t want to have a presence here in the States, uh, that wouldn’t necessarily be subject to, you know, the, the foreign entity qualification, uh, restrictions to qualify for tax credits. So there are possibilities for this long term. Does

Allen Hall: it leave a door open for a company to come in and clear the books, settle the debts on some level, and then you continue on as a restructured company?

Joel Saxum: Or this, or think about this one. And, and this is, this is a long shot, right? But does it leave a door open for someone to watch TPI fall on their face and start [00:28:00] up a blade company?

Allen Hall: I don’t think so. That’d be hard because there’s so much, there’s so much momentum right now with TPI. It’d be really hard to do that, be like, I’m gonna use an aerospace equivalent.

It would be like Boeing Aircraft and Spirit. And Spirit was Boeing at one point, then broke off and set up their own company and was supplying pretty much all Boeing. Uh, parts, but Boeing has reacquired it because it came in in trouble, very similar to the TPI situation. Not that TPI was owned by an OEM, but it does sort of lend itself to ge.

Renova designs are coming through TPI all the time in a couple of the manufacturers, for that matter. Somebody’s gotta do something. They need parts.

Phil Totaro: Yes, but here’s, here’s the reality and ’cause I’ve actually studied a bunch of the different m and a deals that have happened in wind energy over the years.

What happens in most industries with m and a is healthy company buys smaller, healthy, but growing company. In [00:29:00] wind energy, we don’t really have that. When m and a happens, it’s usually healthy company gobbles up assets of, you know, unhealthy company that are still valuable and then leaves the debt to somebody else like, and that’s why.

The chapter 11 thing is interesting because if they’re restructuring the debt, it means they can reduce it a little, but the debt is still gonna be there. If I’m going in and saying that the company’s worth 7 million in a valuation, but they have a billion dollars in debt even after, or during chapter 11, I’m not buying it.

Um, because who wants to absorb that? Nobody, nobody wants to do that. So the reality is, what Joel mentioned is are people gonna watch while this thing falls on his face? And then out of the ashes of, of this something new, uh, arises? Yes, I will actually agree with and support that notion. Not that I’m hoping TPI fails, but.

That’s [00:30:00] more likely to happen if the worst transpires and TPI can’t pull themselves out of this. That is more likely to happen than some, you know, angel investor, uh, or angel of an investor, uh, swoops in and, and grabs them up and, and says, you know what? We’re, we’re gonna. You know, keep you healthy and keep you going because you’ve got this $1.6 billion order book.

What, what we have in the wind industry are vultures who come in and they start plucking away at that $1.6 billion worth of order book and taking it for themselves. And, you know, the remnants of that carcass can go, you know, die in the desert somewhere.

Allen Hall: No, I, here’s, here’s my. 30,000 foot view of TPII hope they can make this work.

There’s a lot of workers and a lot of the wind industry that relies upon them. They cannot close. They need to keep producing and, and everything that’s happening in the world right now, uh, with Sted [00:31:00] is not great. But TPI has a bigger impact I think. In terms of where we’re going over the next five to 10 years, we need blades.

TPI makes a lot of blades. They’re pretty good at it, but the financial situation is just not good at

Phil Totaro: the moment. And keep in mind too that because of these changes in the law for production tax credits and investment tax credits, TPI needs to keep producing blades for now. Uh, which is one reason they were probably able to get this, uh, Oak Tree Capital.

Um, you know, financing, uh, to help them continue operating because they have to make deliveries for anybody that’s got, uh, turbines that they wanna safe harbor before the IRS rules change again, presumably at the end of this calendar year, we’re about. You know, another what, 15 to 20, 20 days away from seeing the first draft of whatever these IRS rules are gonna [00:32:00] be.

I’ve already covered, you know, ad nauseum. I think it’s the 18th or 20th. It’s soon. That’s what I mean. It’s supposed to be, you know, in, within the next few days here, um, that we see a first draft. But just keep in mind that a first draft is not the adoption of the rules. So we’re. We’re expecting that the final rules will be fully adopted by the end of the year.

If you haven’t safe harbored under the current rules, you need to do it now. That’s by the way, why Vestas just announced a 950 megawatt project in the us. Uh, they didn’t say who. Although if you want the details, contact us, uh, Intel store. We know. Uh. So, you know, the, but the reality is anybody that needs to safe harbor turbines needs TPI, particularly ge or even Nordex if they’re, if they’re, you know, getting some of these blades from Mexico, uh, now that most of their, their quality issues I think have been worked out.

Allen Hall: That’s gonna do it for this week’s Uptime Wind Energy podcast. Thanks for joining us. Check out [00:33:00] our uptime tech news where we talk about these subjects and a whole bunch more every week. It’s free. Just Google uptime tech news and you’ll get there. So we will see you next week here on the Uptime Wind Energy Podcast.

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Morten Handberg Answers the Big RCA Questions

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Morten Handberg Answers the Big RCA Questions

Blade specialist Morten Handberg on when an RCA pays off, what SCADA data can and cannot tell you, and why erosion gets written off as wear and tear.

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Allen Hall: Morten, welcome back to the program.

Morten Handberg: Thanks, Allen. It’s so– It’s, it’s so such a great, great pleasure to be back again.

Allen Hall: We have a lot to talk about today because of root cause analysis and the number of operators that are really struggling with RCAs, of when to do them or when not to go down the RCA pathway.

It, it– There’s a, a ton of confusion in the industry about it, and we thought, well, this would be a great time for Morten to come back and explain when is the right time for an RCA. So Morten, when is the right time for an RCA? What should we look for? Or wh- how big of the problem sh-should it be [00:01:00]before I find somebody to help me do this RCA?

Morten Handberg: So the obvious question is typically when something really bad happens, then I think everyone can agree that, you know, we should definitely do an RCA to get to the bottom of this. And that’s also just from a– It’s both from a technical perspective to sort of figure out, you know, why did this happen, and, you know, um, who…

Well, what is the, what is the main cause? Is it, is it something that, you know, it was happening while we were operating the asset, be it turbine or whatever? Uh, was it something that was inert in the bla- in the, in the turbine, the blade, the gearbox that was just waiting to happen? So that’s always very important to know.

Also because it tells you what is the chance of this happening again, you know, and, and can you prevent it in a meaningful way? Um, and there’s also a, a safety aspect to it because it’s– so it also tells, you know, uh, what if, you know, you don’t want blade falling left and right. You don’t want gearbox ex- [00:02:00] gearboxes exploding.

You don’t want towers to collapse. We can all agree on that. Uh, and you don’t want this to happen because you don’t, you don’t want to run the risk that someone gets hurt, uh, hurt by it. So then RCA is a really important tool to investigate and find out, well, what happened here, and how can we prevent it, and what is the chances that it happens another time?

So that, that is sort of the– That we can always agree and we would do it when, when something really terrible happens. Then there is the, you know, not so critical ones where, you know, you are just in time, uh, that, that, that you catch it, and then the question is, what is the– when is then the right time for that?

Allen Hall: There seems to be a couple of phases in the lifespan of a turbine where the RCA, it becomes a little more critical. In that first year or two, particularly if the turbine is under warranty or you’re getting close to the end of the warranty, there– at least from a lot of operators I have spoken with, that, uh, [00:03:00] they would like to do an RCA as more of a documentation of what has happened on the site to then maybe claim serial defect maybe l- at another point.

There’s just like the record-keeping part of RCAs, which I’m not sure is the right level of effort for what you’re trying to accomplish. Is, is the RCA the right approach there if you have a, a gearbox issue or a blade issue early in the life cycle of a turbine?

Morten Handberg: There is definitely before the end of warranty, there is a, there is an, there is an aspect, you know, when should you actually do an RCA?

And it should, it, it should benefit you in a way where you can– where there is an economical benefit, because it might not be a massive critical issue, but something that will lead to a lot of maintenance down the t- down the line. Um, but if you want to make it successful in the warranty claim, then you really need to know what is the, what is the cost behind it.

Is it wear and tear? Is it [00:04:00] a manufacturing defect? Is it, uh, environmental conditions, uh, that are, that are causing it? And these, these becomes really important. That’s also why you can, you, you can, you can do an RCA on erosion, uh, because it, it can be important if you see massive, uh, erosion degradation that you really want to understand, what are my local conditions?

Um, and a good example here is Australia, because Australia doesn’t work like Europe. We– You can take all the experiences we have from Europe, but it does not work in Australia. So you might want to do your, your, uh, root cause on that specific issue localized, uh, to really understand it, and that’s when RCA becomes really strong to sort of find out what are the underlying mechanisms, uh, that enables this.

But you can also pour in a lot of cost and effort into relatively minor defects, uh, or issues, um, where it does not really benefit you in the long run, and that will always be a challenge before end of warranty because you don’t really know what will, [00:05:00] what will hit you down the long run, and that’s where you, you know, then, then it becomes more of a strategic decision.

You know, breaking bolts, if you’ve seen one, maybe you don’t want to do an RCA on it. That does not really seem to matter to you that much. It’s just random occurrence. But if you start to see it, uh, in, in quick succession on multiple turbines, adjacent bolts, then it’s important for several reasons. One, you might– If you’re still within warranty, you really wanna know why is this happening and, and how do you fix it long term so this not– does not become a headache for the next 25 years?

Um, so you want to, you want– you really want to understand that. And two You can, you can live with a few broken bolts on the blade, but there, there will become a critical point where the blade will liberate and then, uh, it will, it will col- it will, it will, yeah, leave the turbine or, or collapse on its own, uh, depending on the turbine model.

And, and that is really critical to, to, uh, to avoid and, and to, uh, to [00:06:00]understand that. Um, and maybe the outcome of the idea of the RCA is monitoring, but that is a really important knowledge to have.

Allen Hall: That’s a good point about the monitoring aspect because I think a lot of times when a operator chooses to go down the RCA path, what they’re expecting is just to get a report of this is the conditions that created the damage or created the unexpected outcome Uh, it, sometimes you may not be able to get to that final answer, and the answer can be, we need to put conditioning monitoring on to have a better understanding of what the fault is.

That’s not a invalid RCA. That’s a really useful tool. But a lot of operators don’t think of an RCA as being that sort of outcome. That, that is actually where a lot of the industry problems can be solved, right, is to get the engineering up in upfront to then maybe have a little longer time or maybe instrument another [00:07:00] turbine to see how big this problem is.

I- is, is that the approach that which you would, uh, aspire to apply to some of these wind sites today?

Morten Handberg: I think that monitoring, uh, understanding the monitoring requirements is a very critical point, uh, outcome of an RCA. Both– And you can use it both during your investigation to sort of find out when you have, you know, uh, to, to find out how do you detect it efficiently, uh, but also what are the right methodologies and what is it actually that you want to achieve, uh, with mitigating this issue, and then what, what kind of, what kind of monitoring do you need.

So for instance, if you have, if you have, if you have cracks starting in your laminate, you know, do you need acoustics? Uh, do you need deflection monitoring? Um, is it es- is it vibration monitoring, or is it, um, or is it some kind of, uh, video monitoring, um, that or, or infrared scan that, that, that you need to, to keep, um, to, to, to ca- And again, the essential [00:08:00] part is then how do you catch it in time that it does not become a critical issue?

Uh, and, and then by using the RCA to find out, well, what is the best methodology to, to detect this and detect it in a cost-effective way, uh, that, that leaves you in, in good shape to, to maintain your turbines. That is a, you know, that is a really strong value proposition for the RCA.

Allen Hall: Morten, when I talk to a lot of operators about doing an RCA, uh, they don’t have access to high-speed scada, scada data.

They, they have access to low speed, depending on what their arrangement is with the OEM. Uh It’s really hard to get the high-resolution data, and they do not have the algorithms that maybe be able to tell them something about the turbine. They’ll just have sort of raw data streams. How important is it to get some of that high-speed data and the understanding of how that turbine is working as a, a fault [00:09:00] happens or s- some sort of failure happens?

Morten Handberg: It kinda depends on what it is that you’re, that you’re looking for. So for a lot of… for, for, so for SCADA data, it will, it will give you, um, a more holistic view of what, how the turbine is performing. It will give you the power production, wind speeds, wind turbine, uh, the blade pitching. Um, so it kinda gives you an understanding about how it is, how, how it is operating, but it st- does not really give you any specifics about the condition of, of the blades, of the gearbox, of the bearing, of the main shaft, of the tower.

So, um, so it does, so you don’t really have any, any detailed sense of that. You do have alarm logs, and they can be quite important. But in order for, uh, to sort of, uh, to tie that in with the failure that you’re seeing, you have, need to have a very, uh, a very strong sense of, you know, have, need to have an accurate sense of when did this actually happen.

So establishing the timeline of when the failure occurred, that, that sorta increases [00:10:00] the value of SCADA data. Um, so you can– The, one of the things you can learn from SCADA data is you can see the performance was, were, versus what, how the power production is. And then you can start to see, you can start to see how the, you know, if there’s any deviation, um, uh, that ties up in environmental conditions that, that sort of, that would affect the, the, uh, any of the turbine components.

And then SCADA data can be a very, uh, very important tool in addition to your other analysis. But you still need… But SCADA data is only a part of it, and it will only give you a s- a sense of, uh, com- with the alarm logs, it will give you, it will give you, it sorta help you build the timeline of what actually happened here.

And I can give you an example. So- If we’re looking at a blade failure, and we sort of know, well, the blade broke in half at a certain point in time. It was, uh, a very rapid occurrence, so it, it was not something that happened over a very long period of time. It was, it was a quick succession. When [00:11:00] did we start to go wrong?

Um, then scatter data can be really good to sort of, you know when it failed because the turbine did restart. But was that when things went wrong? Not necessarily. Uh, there could be times before that when you could have had tower oscillation, so shock effects. It can, it can be, um, it can be, uh, alarms from the pitch system that says, you know, the, that there is something with the blade.

It does not really behave right or that it can’t really turn right. Um, and/or the, the turbine does not really produce as it should. That can then, that can then help you establish, okay, how far back is this actually? When, when does this really start from when it collapsed and then when does the issue started to occur?

Um, so then, then, then scatter data becomes useful, but it’s not something that will tell you it was lightning, it was manufacturing, uh, or otherwise. That scatter data doesn’t really work for that, but it helps you establish the timeline of it.

Allen Hall: All right. That’s very interesting, uh, because I think that plays into some of the questions about [00:12:00] insurance and when you have a damage or some situation where you have had exceeded the deductible, right?

So you’re, you’re, now you’re into a couple hundred thousand dollars of a claim of some sort. There’s two opposing opinions about RCAs that right there is, one is I’m gonna file a claim. The insurer will perform the RCA and come back to me with what actually happened, and then we can figure out the financial details.

The other side is, I wanna have an RCA so when I hear back from the insurer, uh, that they, uh, my RCA aligns with their RCA, that we’re in agreement. And if we’re not in agreement, uh, how do we handle the difference? What is the right approach there? Is there a right approach there?

Morten Handberg: Often where you would start is, uh, you would actually a- if, if there is an issue and you’re, as an operator, is concerned, you would often start with going to your OEM and saying, “Hey- We see [00:13:00] this.

This does not seem right, or this component failed. We need you to provide an, an RCA and if you have a good contract, then the OEM is obliged, uh, to provide that. But that will state, that will be stated in, in your contract if they are required to do so. So I would, I would use my contract for that. Then if, uh, they don’t are required to perform an RCA, they don’t want to, or you’re unsatisfied with it or, and you have filed an insurance claim, then, uh, then there might be an obligation for you to carry out an RCA.

Or there might be a strong desire for you to sort of either find out, well, is the OEM right? Um, or is there something I need to challenge them on here? And then an RCA become– And that, that, that’s when you want to do your own RCA. Uh, and then whether or not you, the insurer, uh, will do an RCA, that, that sort of depends on the, on the process of the claim.

Uh, if there’s any, uh, if there’s a [00:14:00] contes- some, some contention, uh, between the parties. Um, more often than not, there is, there is a, there is collaboration between all parties if all are interested in, in seeing things coming to, to the right end, and that they use– sort of let the RCA be the, be the guiding star and that everyone can agree, okay, whatever the outcome of the RCA is, we’ll stand behind that as long as it’s carried out in a professional manner.

And these different boxes that we want to have checked, that they are all verified and there’s documentation for it. So it can be an, it can be a good tool to, uh, to sort of, uh, have an alignment on the, um, on, on a, on a claims process, really.

Allen Hall: I wanna touch on how the OEMs play into the RCA. So l- let’s use the example which is happening here in the United States quite a bit, and also in Europe offshore, which is leading edge erosion And the question regarding wear and tear versus something that’s a claim, and [00:15:00] if ex- there’s been accelerated leading-edge erosion, trying to put a root cause to that.

Is it a manufacturing issue? Is it a location issue? Is it a maintenance issue? It could be all of them or a combination thereof. Uh, how does that work? And is the RCA the right approach there just to put some markers in the ground as to what the issue really is or the underlying causes are?

Morten Handberg: Yes, but it has to be an independent RCA.

Um, because there, um, if there is invested interest in having one result over the other, then there will always be distrust between the parties. Um, you know as well as me that a lot of leading-edge degradation, I would say, is being marked out, marked out as leading-edge erosion. Uh, but from some of our previous talks then, you know, there is very much difference in leading-edge erosion defects because you can have scratches, you can have voids, you can have, uh, peeling, chipping, and you can have erosion.[00:16:00]

Um, but and, and they look very distinct, but often they get thrown into the same category, and they get thrown into the same cause, being wear and tear, which is ridiculous because, um, a lot of it is, uh, uh, uh, you know, some of the key defects they’re manufacturing with, uh, driven. So peeling and voids, that is manufacturing, and they are driving a lot of the erosion.

But if that gets masked as erosion, then, well, it’s just an environmental de- effect, so we can’t really tell. And I think also, you know, a lot… there’s a lot of, uh, issues regarding leading-edge protection systems peeling off, and then they don’t work as well, which is also somewhat, you know, we, we talked about this before ear- earlier in the podcast, you know, Australia having their own issues.

I think one of the issues that they have is environmental conditions, that’s very obvious, but that leading-edge protection systems are notoriously difficult to install there because of the hot and at times humid conditions, and they don’t work very well with a lot of [00:17:00] leading-edge, uh, products. So that would mean it’s not an environmental effect that caused a leading-edge erosion, uh, systems to fail, to fail.

It’s the application. Um, does that mean that Australia need their own product? Yes, but they need systems that are reliable and applicable in their con- in their conditions that will lead to, uh, stronger durability. And again, that’s what you need the RCA to, to, to figure out. And if you have a, an RCA carried out by someone who wants it to be wear and tear, then regard- then unless you can…

they, they, they come up with something else than wear and tear, you will always have a, a slight distrust in the result. So that’s why I would always argue, if you have concern for leading-edge erosion, then absolutely go to your O&M, figure out if they have a– if they’ve seen it before, they are keen to, to engage and provide a suitable solution and, and, you know, share actual knowledge.

But I would always keep in back of my head that if, if you’re not [00:18:00]100% sure about their– them telling the right– you– they’re, they’re telling you the truth, I would get it sanity checked, and I would carry out my own independent study which is what a lot of O- O&Mers are doing.

Allen Hall: That’s a really important bit of information for sure, Morten.

When going out to look for an RCA provider, what tends to happen, at least in the United States, and I think, uh, Australia can be this way at times and, and Europe definitely is, is that the chosen supplier of the RCA is one of the acronym companies. We all know who we’re talking about here. Just because they’re large in scale and they have a lot of capabilities, they have a lot of engineers, and, uh, they b- some of these things are pretty routine, and it does seem like they can, can do this job.

But I’m seeing more and more independent companies doing RCAs because of the level of detail. Some of the bearing issues that have popped up really require an expert in [00:19:00] bearings. Some of the tower issues require someone, especially foundation, someone who’s knowledgeable about concrete. Uh, same thing for lightning.

Usually you need somebody who knows something about lightning to be involved instead of a, a, a larger organization. What are you seeing in that space today? Are you seeing more, uh, narrow focus, uh, independent groups or engineers working on RCAs, or is it still mostly the big companies that we all know?

Morten Handberg: I would say that, uh, all of the acronym companies, uh, all have very good, talented engineers employed.

I don’t think we need to d- you know, we can all agree on that. But, uh, what I can sometimes be concerned is whether how much politics plays into their, um, their output. Um, so what would be important for me if I was, if I own a wind farm and my expertise is blades. So if I needed someone to look at my tower or my, my gearbox, I would find an expert within that [00:20:00] field.

I would definitely find someone in my network or, uh, uh, or, uh, otherwise that I know can provide an independent and honest opinion without, uh, having any any relationship to any of the OEMs or component suppliers, um, including the, including the coding suppliers. They’re all good. They’re all, uh, very, uh, all, all very skilled, have good products.

But they’re gonna want someone to look at, you know, what is the best solution for me with what is out there, um, and not be blindsided or focused on what is, you know, uh, other in, in interest in that.

Allen Hall: Right. Because it, it’s, it’s sometimes hard to tell where y- everybody’s intentions lie. It’s like hiring an attorney, I think, at some point, and that’s what I tell people is it’s like hiring an attorney.

Do you want an attorney that’s on your side, y- y- or and helping you? Do you want someone who’s more like a judge that’s just an independent person [00:21:00] or, or an advocate? Like, what are you looking for exactly? And it, uh, you need to think that out, uh, before you make your selection. And a lot of times there’s just a couple of defaults, which I have Have done really well, obviously, because the larger firms have a lot of engineering experience and have seen things globally, but not necessarily– That’s, that doesn’t mean they’ve seen your particular, uh, problem, particularly on a, on a new turbine design.

Those are really difficult RCAs, in my opinion. And Morten, you see this all the time on new turbines. Like, those are the

troublemakers in, in– from engineering to try to solve the problems ’cause they’re, they’re new.

Morten Handberg: Yeah, and we’re, we’re, we’re playing catch up, uh, with the, with the technology, and we’ve, we’ve been, been, been like that for for quite a few years now. And, and whenever, uh, a, a new blade that is, uh, ten meters long, well, we think we know what the, what the previous versions, how they worked and, uh, and what, what could go wrong with them, and that’s both in terms of the structure, in terms of the, uh, storage, in terms of, of lightning.[00:22:00]

But it seems like, you know, there’s some-always something new popping up, uh, and also in new environments that we’re installing turbines creates new problems that we haven’t really foreseen. And, and again, if something that you’re not expecting then suddenly starts to appear, that’s also when you, you really want to, to use the RCA tool to, to sort of get to, uh, get a handle on what is going on and get an– and get that deep dive understanding about what it is, because it will help you, uh, uh, understand, well, what are my risks going forward, and what can I do to mitigate?

Uh, and, um, yeah, on, you know, uh, and is there, is there, is– Do I need to, to look at, uh, putting a claim together?

Allen Hall: Morten, this is super helpful. I know a lot of operators around the world, uh, really question when to do an RCA, and if they should be doing RCAs, is it worth the spend? And you’re a great resource on that just because you’ve done a number of RCAs over the years, and you’ve been involved in [00:23:00] other companies that have performed tho-that task, and you have a, a sense of reality there of, uh, probably not an RCA, but probably some engineering time.

Or no, you really, really need to be on an RCA right now. How do people get ahold of you and, and to pick your brain about that an-and to get some, some knowledge, uh, to help them make their decision?

Morten Handberg: Um, yeah, you can always look me up on LinkedIn, and I am always happy to engage. Uh, if anyone has a question on, on blades or on RCAs or on maintenance, um, my door’s always open, and I’m happy to have a chat, uh, and share my knowledge.

That’s how I’ve been operating for my entire career, and that’s how I intend to continue. So please feel free to reach out, and ha-looking forward to, to the, to the discussion.

Allen Hall: Morten, it’s great to have you back on the program. Looking forward to having you again in the future.

Morten Handberg: I, I’m loo-looking forward to many more, more, more, more times on your show, Allen.

Thank you so [00:24:00] much.

Morten Handberg Answers the Big RCA Questions

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