Published

5 months ago

March 17, 2026

Alice Rush

Weather Guard Lightning Tech

UK Drops Offshore Wind Tariffs, Ming Yang in Germany

The crew discusses the UK removing tariffs on offshore wind equipment, Vineyard Wind’s final blade shipment from New Bedford, and Ming Yang joining Germany’s offshore wind association.

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!

The Uptime Wind Energy Podcast brought to you by Strike Tape, protecting thousands of wind turbines from lightning damage worldwide. Visit strike tape.com. And now your hosts.

Allen Hall: Welcome to the Uptime Wind Energy Podcast. I’m your host, Allen Hall. I’m here with Matthew Stead, Rosemary Barnes and Yolanda Padron.

And the UK is really gearing up for offshore wind and they’re making some really smart moves and. One of them is, uh, the change in tariffs. So the British offshore wind manufacturers have been fighting really an uphill battle for a long time and for years. The companies that build turbines and components in the UK have faced import tariffs on the materials needed most, which tends to be steels like steel.

Uh, cables, specialized parts from overseas all carried a tariff with it. Well, now the federal government has acted to [00:01:00] remove those tariffs on offshore wind equipment. The move is expected to save UK manufacturers tens of millions of pounds every year. And for an industry trying to cut costs and scale up that kind of relief could make the difference between winning.

Losing contracts, and I’m surprised the UK has waited this long and I think other countries have the same problem. Obviously the US is taring the heck out of everything at the minute, but uh, a lot of European countries do put tariffs on the raw materials and the components that are used to make wind turbines.

That’s not a smart long term move if you’re trying to deploy. Gigawatts of offshore wind.

Matthew Stead: Well, I, I think, uh, the recent events in the world show that energy security and not importing energy is a wonderful thing. And so this completely aligns with that, um, that objective. So I think that’s why we all agree with you, Alan.

Allen Hall: Well do, is there a, a. A threshold here where other countries start to do it [00:02:00] and for whatever reason there’s, there’s tends to be tariffs on energy in all forms of it. Right. And there and on steel in particular, that seems to be a big area of concern. Are we gonna start to see some of those come down just to lower the cost of wind turbines and to deploy the middle of the water?

’cause there is a lot of steel in an offshore wind turbine.

Matthew Stead: It’s been like China. I mean China has, you know, a lot of clean energy, low cost energy and it is to their advantage. So I, I think it’s a entirely logical approach and I would’ve thought it’s, if you’re a good on policy, you would definitely be looking at this.

Allen Hall: Is this has been a concern of the UK steel industry, which has been diminishing over the years? Uh, so it’s always been a pain point with the uk. They’ve been trying to stand up their own steel industry and forever they had a big steel industry In the uk you think of all the. The steel that was built from late 18 hundreds all the way up to the 1980s and nineties.

Uh, but it does sound like you, you gotta pick and choose your battles here. And maybe the UK has [00:03:00] finally said, okay, the, the steel battle is a separate issue within offshore wind, and maybe we gotta do something different.

Matthew Stead: I mean, I think Australia did the same thing ages ago. I mean, we had a car, car industry and you know, we just didn’t have the scale.

So, you know, Australia’s picking its battles and um, yeah, I mean, you can’t be good at everything, so you know why not. Uh, get the, the lower cost energy and um, deal with it that way.

Rosemary Barnes: Australia has actually just announced, you know how Australia’s got the policy to support clean energy technology manufacturing in Australia.

And they started with, um, solar panels and then they’ve also got something related to battery cells. Well, they just announced wind turbine tower manufacturing, um, which is very simple. The reason why Australia doesn’t have, um, wind turbine tower manufacturing anymore. Is just because we can’t compete on price with Asia, um, in general and China specifically.

It’s interesting now to be like, okay, let’s support Australian [00:04:00]manufacturing of wind turbine towers when like there’s no technological barrier. It’s pure cost, cost issues. I would really love to see the Australian government supporting some of the new manufacturing methods and you know, like we’ve seen that Fortescue has invested in.

Um, in Ena Lift, the Spanish, Spanish company, um, ESCU has, has bought their tower manufacturing. Um, it’s, it’s like modular, advanced thing that’s gonna work well for remote areas. Otherwise it’s just like, pay a bunch of money so that we can make towers more expensively, but we can sell them at a competitive rate with the Chinese.

And I don’t know, to me that’s not very strategic. I always prefer we support the next, the next thing.

Allen Hall: Whatever happened to spiral welding and making towers on site. I think that died about a year or two ago because they were trying it here in the United States and about building ’em at the wind farm.

But it sounded like just setting it up to [00:05:00] build the spiral mechanism, the, the cold, uh, forming plus all the welding on top of it. It got to be so expensive to install on site that it was just easier to, to build a central location, which I think they were going for. I’m not even sure that in today’s world, because of the advanced technology in the existing way of manufacturing is so good and inexpensive that it makes any sense to try anything else.

It just seems like it’s, there’s just stamping out parts right now.

Rosemary Barnes: Oh, no. I mean, we definitely need new, new methods because we’re really constrained on how tall towers can get if you just wanna make a steel cylinder and ship it out in, you know, whole pieces, like whole cross sections and. Um, put them together vertically.

That’s you. You know, like we’ve, we’ve gotten about as tall as we’re gonna get for that because if you want to go any taller, you’re gonna have to start massively increasing the thickness of the tower to make it stiffen up. And that just means way more steel to keep material costs reasonable. You need to increase the diameter, um, beyond [00:06:00] what you can transport on the road.

Um, but I think that it’s like the, the, the problem is definitely real and well established, but it’s like with many other. Problems. You know when you start thinking, okay, we’ve got a solution to this problem at that time, there aren’t other solutions, so you’re sure that you know you’re gonna win. And so spiral welding was one of the early ones.

Oh, we can fix this problem, but. While they’re developing that and trying to get the capabilities where it needs to be, the cost down, you’ve got a dozen other competing ways that you could solve that problem. And they include like, um, some manufacturers, I think Vestus is one. They’re cutting longitudinally.

And so instead of, um, shipping out towers in a single cross section, it’ll be like four. And then they’re bolted together on site. Um, and then Concrete Towers is another one. The Naber Lift, um, thing that I mentioned.

Matthew Stead: Wooden towers.

Rosemary Barnes: Yeah, wooden Wooden towers is, uh, another one I’ve covered, uh, [00:07:00] on my YouTube channel.

Matthew Stead: They really should make them out of carbon fiber, shouldn’t they?

Rosemary Barnes: Well, I have, it’s not, it’s You’re saying that as a, as a crazy thing. It’s not, it’s not such a crazy thing. And I have, I have, I have looked into it. You wouldn’t do it outta carbon fiber. You’d do it outta glass. Um, there’s a lot of. There’s a lot of benefits to it, and I actually do believe that we might eventually see like 3D printed glass, um, towers.

Allen Hall: No.

Rosemary Barnes: Now we’re just getting into our standard. I, I believe the future might look different to the, to the present day, and Alan never thinks that anything’s ever gonna change.

Matthew Stead: I would’ve. 3D uh, printed concrete towers would have some logic.

Rosemary Barnes: There’s been pilots of 3D printed concrete, concrete towers. I’m, I’m pretty sure GE had a, um, a project on that and there might have been somebody else that did, took it a bit further.

It’s all possible. It’s also like concrete towers are, are good, but it is local. Like it depends on having the right materials around locally. ’cause you don’t want to have to transport Hess of. Concrete and water to site. Um, [00:08:00] so yeah, anyway, the point is that like, just because you’ve identified a real problem and you’ve got a solution to it, if you are gonna take five or 10 years to develop your technology and get it to the right price point, you are not gonna be the only, the only solution anymore.

So people often like massively overestimate how valuable their idea is. Um, and by the time that it’s ready, it’s not the best solution anymore. So I think like the lesson from that is to just. You need to just move really, really fast and keep your peripheral vision available to see what other technologies are developing in tandem and know when, when to pull the pin.

If you are no longer, you no longer have a path to be the best solution, then. Stop. Even if you’ve got 90% of a solution, don’t bother with the last 10%. If you’re never gonna sell it, you know it’s a waste go. Um, let, let all your smart people work on something else.

Allen Hall: Delamination and bottom line, failures and blades are [00:09:00]difficult problems to detect early. These hidden issues can cost you millions in repairs and lost energy production. C-I-C-N-D-T are specialists to detect these critical flaws before they become expensive burdens. Their non-destructive test technology penetrates deep to blade materials to find voids and cracks.

Traditional inspections, completely. Miss C-I-C-N-D-T Maps. Every critical defect delivers actionable reports and provides support to get your blades. Back in service, so visit cic ndt.com because catching blade problems early will save you millions.

Can we pull the pin? On digital twins. I came across another company that was pushing digital twins in the wind turbine space. And I thought, I thought we got rid of that a year ago. Can we stop doing that?

Rosemary Barnes: I, um, in general, like I think a lot of times you see digital twins and I can’t see the point, but there are some applications where you [00:10:00] definitely can,

Matthew Stead: uh, I can add on the digital twin, so the IEC 61 400 dash 32, the new blade o and m standard has in the, in its current draft, it has a section on digital twins.

Um, and um, at the last meeting there was a debate as to whether that should be taken out because actually, um, AI, ml, um, all these, um, approaches will just overrun the concept of the traditional digital twin. So, um, I was voting for it to be removed, um, but. Other people didn’t. And so it’s still in the current draft.

Yolanda Padron: I am a little bit tired around digital twins at the idea of, like, I’ve seen the title slapped around a lot of things that just aren’t digital twins. And I think that gets even more confusing to a lot of people who are just new to the space or new to the idea that then they, they, they hear digital twin, they have like an idea about it or like, oh, it’s really great, and then they pursue something that just [00:11:00] really isn’t, it’s just a.

A monitoring system that they wanted to name something else.

Allen Hall: Yes, that’s it.

Rosemary Barnes: I’ve seen it used well in manufacturing, which is not usually what people are selling it as, but you know, if you have a new composite part, for example, and like a wind turbine blade is a really good example, you design it. And then you can only test it to a certain extent.

Um, and you never know exactly what you’ve made, right? And so it’s really hard to kind of relate, like to validate your design tools when not every blade is the same. You know, it’s aiming to be the same. The design is the same every time, but you’re gonna get different results every time you test it. But with some advanced, uh, manufacturing, like my favorite thing to argue with Alan about 3D printing, um, fiber reinforced composites.

You can really precisely know exactly what your part looks like all through the structure. You know where every void is. Um, you know where every fiber is and then so you know that exact part. Then you can test that exact part, and you do that with, you know, a dozen of them and you can really [00:12:00] build up a model of what kinds of defects are really, um, you know, doing what to the performance output.

And then that can help you to get your quality, um, acceptance to really, like you, you can do the things that matter instead of guessing, oh, okay, yeah, we know that we want this much. Bond line, you can actually know, okay, well like where does that matter? Where doesn’t it? What’s the actual threshold?

However, it’s very expensive to do that, and I don’t know that it would make sense for wind turbine blades economically, maybe. Maybe it will one day. I mean, if we can get the quality data that we need, there are big pro quality problems that need to be solved with blades so. I think it’s something to not totally rule out anyway.

Matthew Stead: That’s quality control. That’s not a digital twin.

Rosemary Barnes: No, but it is. You have the di you have the make up a digital twin of the, of the part that you’ve made, and then you test it and then you can, um, digitally test the [00:13:00] part that you, the model that you have. So it is a digital twin. Um, it’s just used in a very different way to what digital twins are usually sold as.

It’s not at the right level yet for a hundred meter long. Composite wind turbine blade. Um, and also because you would need to destructively test, you know, a, a whole bunch of blades which no one can afford to, to do that.

Yolanda Padron: What if we were to take all the money from like FSAs and stuff that they have to spend, like the OEMs actually have to spend from all of the manufacturing defects from, oh, I tweaked this on this blade type in this.

Factory and set it to print and then I tweaked it over here and then I set it to print for like hundreds and hundreds of blades. Um, you know, all of that money spent accumulates too, if we really wanna look at the business case. But eventually, I think maybe it’d be great if it were to work out. I am also.[00:14:00]

Hoping

Rosemary Barnes: I, I think it would be a really interesting project to work, and I bet I could. I, I bet that, you know, a good project manager could get, get a positive business case out of it. At the end. One of the problems is that like service, the service department bucket of money is not at all related to the manufacturing bucket of money.

Um, so, or the, yeah, the engineering back of the money that, that, that would be a really big problem and make it harder to find a positive business case. But I still think that it’s, um. Yeah, it, there’s a lot of potential there. It would be really interesting project to work on.

Matthew Stead: In terms of the operational phase, I, I think, um, like I said before, the A IML tools.

A way more powerful with anomaly detection rather than building a, a fancy digital model, which is not accurate. Um, actually you’re better off looking at the deviations and then the anomalies from what you expect. And I, and there are quite a few people that are doing that, and I, I personally think that’s a way more effective method during the operations and maintenance phase.

Rosemary Barnes: But I think that that [00:15:00] would be related. It would be a way to improve what you’re doing there because you said, yeah, digital twin, that’s not. Accurate. So you would need to be accurate. That would be the project to figure out like how you can get accuracy in the right places that you need it. You wouldn’t be able to afford to have accuracy over the entire blade ’cause it’s just way too much data.

And then, um, it would help you to figure out like what anoma, what anomalies do we need to look for that are the, the critical ones. I, I think that they would, they would work in partnership. Um, not as two separate things. Can I just plug, because I’m gonna go to China in April and can I just plug that if anyone has any projects, I’ll be there anyway.

And um, yeah, so I am sharing the cost of the trip between a few different collaborations and there will be a chance. To, to get me out there to see some manufacturing, et cetera. Would be really excited to go visit some Chinese [00:16:00] manufacturing, some Chinese development. Got a few, few tentative irons in fires at the moment, but would love to have Chinese companies reach out to me and see if we can arrange a collaboration

Allen Hall: 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 wind.com today. It has been a turbulent chapter in offshore wind in America. No doubt about that vineyard wind. The first large scale offshore wind project in the US has faced a crazy difficult road after months of uncertainty, partial construction, and a federally ordered pause.

The [00:17:00] project has reached a telling milestone the first. And final shipment of the last blade has departed the port of New Bedford, Massachusetts. And, uh, the blades were just sitting on port for a little while. Uh, Keyside. So this is the last blades or set of blades that’s going out to a turbine. This should sort of wrap it up.

I, although I do think there are a couple of blades that may still need some modification updates, something of the sort. But in terms of getting termites out in the water. This should be it. And remember a few months ago, GE and uh, a number of others, vineyard was saying that they’re trying to be done in March.

So they’re going to come really close to doing that. And that I know they’re trying to get power all turned on for the site. Because once that happens, it’s really hard for the, uh, the federal government to put any stops on them. I, I guess the question is now, is there any future for offshore wind for [00:18:00]ge now that this is complete and, and it’s kind of off the books, which is what they’ve been trying to do for the last roughly two years, is get it off the books.

Matthew Stead: Um, as a positive, I mean. You know, every industry goes through challenges and improve. So I mean, despite all the turmoil, you know, there has to be some good come from it, even though it is been a painful, horrible process. You know, surely there’s some good come from it in terms of improved quality in the future, improved processes, so,

Allen Hall: well, I, I guess that’s the question is are they taking some of these lessons learned and applying them, or are they taking the lessons learned and saying we’re not gonna do that again in, in terms of going down the pathway for offshore wind.

Matthew Stead: Well, I think if, uh, if they don’t apply the lessons, that’s sort of, it shows a massive failure of an organization.

Allen Hall: Yeah. It may, I guess it’s a question if it’s a technical failure or a financial failure. Maybe it’s both at the minute until they get everything up and running. But I think the financial side has been.

Driving a number of the, of the decisions because the [00:19:00] technical side hasn’t gone all that well.

Matthew Stead: Uh, I think, uh, I think the financial side is an art, which I don’t understand.

Allen Hall: Yeah. Yeah. There’s a lot of moving pieces in financing offshore wind. Now, Vestas has won a, a couple of big. Uh, orders from RWB offshore and Vestus has obviously been in, in some offshore, not at the scale as originally as some of the other OEMs.

It does look like the future is bright for Vestus offshore. Is that just gonna continue on that? Vestus is going to invest heavily in offshore and basically dominate that market. Or compete against a a Chinese manufacturer. It doesn’t seem like Siemens is gonna win a lot of offshore contracts off. At least today it doesn’t.

You don’t see a lot of noise about that. You see mostly Vestas winning these gigawatt orders. It almost seems inevitable they’re gonna win most of them.

Matthew Stead: Um, I don’t, being long way, way away from where these projects are being made, uh, installed. Um, I don’t have the same sort of insights. [00:20:00] Um, but, um, I mean, obviously yeah, vest, MHI, the previous, um, you know, joint venture with MHI, which especially heavy industries.

Um, obviously they’ve come from a, a long pedigree of, um, working offshore, so yeah, I mean, why not? And, um, it seems to be a more of a gradual ramp up, um, and a more orderly, systematic ramp up for offshore. So, yeah. Why, why wouldn’t that work?

Allen Hall: Well, we should hop on the. China discussion because, uh, China’s when turbine makers obviously been trying to build turbines in, in Europe at scale for quite a while now.

Uh, and Ying Yang is talking about focusing their efforts on. Germany and they have joined the German Offshore Wind Association BWO. And this is not just a membership cards, uh, that they have subscribed to. It is really like, in a lot of people’s opinion, a strategic signal that Ming Yang intends to compete in the European off.[00:21:00]

Market, maybe starting with Germany. Ming Yang was trying to get into Scotland originally, and they were talking about a billion and a half pounds being poured into Scotland to develop factories for offshore wind. Maybe that has come, uh, time has passed and Ming Yang is moving on to Germany. That’s what it reads like to me.

Or, or they’re gonna hedge their bets and, and look at both places to see if they can get a foot. Print established in either country.

Matthew Stead: I mean, reputation matters. So you really need to build up a, a footprint. And why would you apply a scatter gun approach? So, I mean, you know, just targeting, you know, one region or, um, you know, makes complete sense to me.

So, you know, get, get, get some turbines in the water, get them up and running, get them, get the reliability and the, the reputation, and then, and then go from there. I mean, made complete business sense.

Allen Hall: Well, does that mean that, uh, a mean yang is going to have to lose a little bit of money early on to get some turbines in the water just to demonstrate that they [00:22:00] can do it at scale in Europe?

Matthew Stead: I might defer to Rosie, but I would’ve thought they don’t need to, you know, cut costs. I think they’re already cost effective. So you would’ve thought they would just go in, um, with their, their normal product offering and still be successful. Uh, but maybe I’m, I’m on the wrong mark there.

Rosemary Barnes: My understanding is, and I, I don’t know heaps.

But my understanding is with Chinese when turbines, that there’s a separate version for the Chinese market, and then if they wanna sell it internationally, then they need to make a new version of it that will pass the IEC, um, standards and the kinds of, you know, certification testing that everybody in those markets is used to.

So you’re not always getting, or I don’t think you, I think you’re usually not getting the exact same product. So just because the product exists in China doesn’t mean that it is. Um, without risk in new markets.

Allen Hall: Well, I’m, I’m just curious if ING Yang will have to do a complete IEC certification process because they haven’t done it yet.

Uh, is that what you’re saying?

Rosemary Barnes: They do [00:23:00] a, actually a redesign so that they can pass the, um. Certification and then they, yes, they do the whole certification process. However, Mingan hasn’t sold no turbines outside of China. So they have, or it’s not like this is a brand new thing for them that they’ll have to have to, you know, figure out as they go.

Um, they’ve, they’ve, you know, I, I, if they haven’t done it for these specific turbines that they’re planning to manufacture in that factory, they’ve at least done it for others and know the process. Um, yeah, and I think we all know it’s not that hard to pass a certification test, so it’s not like a huge obstacle for them.

But it will add, it will add cost to the, um, to the process and to the product. Probab probably, you know, there are some design changes that will be needed that will increase the cost of the product. So I don’t think that we’re gonna see, um, you know, Chinese turbines from any, any manufacturer outside of China that are as cheap as the prices that you see within China.

Matthew Stead: To be fair though, um, there is a strong, um, Chinese involvement in the IAC committees. So, um, [00:24:00] definitely the, the standards are being used. So, you know, the standards are being used in China, and so I, I don’t think it’s a huge stretch from, you know, the, the domestic product versus the international product.

Allen Hall: That wraps up another episode of the Uptime Wind Energy Podcast. If today’s discussion sparked any questions or ideas, we’d love to hear from you. Reach out to us on LinkedIn. Don’t forget to subscribe. So if you never miss an episode, and if you found value in today’s conversation, please leave us a review.

It really helps other wind energy professionals discover this show for Rosa, Yolanda, and Matthew. I’m Alan Hall, and we’ll see you here next time on the Uptime Wind Energy Podcast.

UK Drops Offshore Wind Tariffs, Ming Yang in Germany

Renewable Energy

Congress Should Address the Climate Crisis

Published

9 hours ago

August 7, 2026

Alice Rush

Asking the congress to “address the climate crisis” is something of a joke. Most of them have their seats by virtue to their allegiance to Big Oil, and, for many, their position on climate change is that it’s a hoax.

Congress Should Address the Climate Crisis

Renewable Energy

IWTG Consulting on Pitch Bearing Cracks, Loose Root Inserts

Published

2 days ago

August 6, 2026

Alice Rush

Weather Guard Lightning Tech

IWTG Consulting on Pitch Bearing Cracks, Loose Root Inserts

Jon Zalar, founder of IWTG Consulting, joins to discuss broken blade bolts, cracked pitch bearings, loose root inserts, and early detection.

Welcome to Uptime Spotlight, shining light on wind energy’s brightest innovators. This is the progress powering tomorrow

Allen Hall: Jon, welcome back to the program.

Jon Zalar: Thanks for having me.

Allen Hall: Uh, last time I saw you, we were in Melbourne- Yep … at WOMA 2026, and that was a huge event. We know we’re gonna do it again next year in March three, the 3rd through the 5th, so you’re invited back, of course- I can’t wait … if you can make it. Yeah. Yeah.

It’s gonna be, it’s gonna be a good time. A lot is happening in the blade world and in the wind turbine world more broadly. A lot of things we’re hearing right now are related to blade bolt connection, pitch bearing inserts still. A lot of that still happening in the United States. What is the current status of, uh, the blade connection issues in the US?

Jon Zalar: I feel like it’s a growing [00:01:00] issue, not super, super fast, but it seems to be getting a little worse. There’s, you know, more bolts breaking at that joint. Um, pitch bearing cracks are, seem to be pretty common. There’s different solutions for it, and then, you know, the root inserts are another thing that we’ve talked about before that seem to be happening more and more, or maybe more and more people are finding them ’cause they’re looking.

Allen Hall: What are the first indications that you have a blade bolt or some sort of joint issue at the root of a blade? What can you see?

Jon Zalar: A bolt laying in the hub bouncing around. Um, you know, from like a– looking at it from, like, the sensors on the turbine, it’s really hard to tell unless it gets really bad. Uh, some of the OEMs have some analytics developed to kinda start to indicate if there is a aero change because there’s missing bolts or root inserts are coming out, and they’re using that as a way to go figure out which ones to go inspect first.

Allen Hall: Really? Yeah. You think [00:02:00] the SCADA data will give you some indication that you have a, basically a little bit of a loose blade?

Jon Zalar: Yeah. I, I, I think because the number of turbines and the number of data points you have, I think there is a pretty good analytic out there right now.

Allen Hall: Wow. All right. I think a lot of our operators have not taken advantage of that.

Is, is that just b- based on the high-speed data, SCADA data, or is it low-speed data you could see that same effect?

Jon Zalar: I believe it’s on the low-speed data as well, but I bet the high-speed data was used to kinda develop it.

Allen Hall: Wow. All right. So that’s a huge help to operators. Yeah. So what are you looking for if you’re looking through SCADA data, what would be the couple of markers there that say, “Hey, maybe we ought to go look up at the– in the hub”?

Jon Zalar: I don’t know exactly what they’re using, but they would basically look for maybe an imbalance or looking for certain components that are being overworked.

Allen Hall: Oh, sure. Okay.

Jon Zalar: Yeah.

Allen Hall: So your pitch actuator may be getting a little bit overworked. It would seem like one of the places- I think that, yeah … that would get loaded, right?

Jon Zalar: Mm-hmm.

Allen Hall: Okay. [00:03:00] And any vibration monitoring going on? Because it, it, uh, in some cases you’re– I’m hearing, like, millimeter gaps-

Jon Zalar: Correct. Yeah …

Allen Hall: between the blade and the pitch bearing.

Jon Zalar: So probably a combination of the ALC sensors, at least on a GE turbine, looking at that. But the PCH box also is looking at the tower vibration, so it could be a combination of all three.

I don’t know the exact- Okay … details, but between all of that, I think there are some analytics that kinda say, “Hey, go take a look.” And then I think there’s some other companies that have- tools that go monitor it.

Allen Hall: Mm-hmm.

Jon Zalar: Dial indicators remotely or even, you know, people going up there with dial indicators to go kind of rotate the rotor and kind of see if there is gapping between the blade and the pitch bearing.

Allen Hall: Is that a safe situation in your– from the gapping? I’ve heard this where they’ve basically took shims and they’re trying to measure this gap or some sort of dial indication. Is that a smart thing to do? Is it even reliable to do it that way? [00:04:00]

Jon Zalar: I, I, I think there’s some reliability there. And like, you know, these are really big parts, right?

So like a little bit of gap, it, it’s probably expected to a point, but growing gaps is where you should be a little more scared.

Allen Hall: So you’re– you would have to go do that quarterly, monthly, weekly? How, how often would you have to do it to see the progression? Because I’ve heard stories of, uh, a couple of weeks from nothing to hub crack to, “Oh, it took a year or more.”

Jon Zalar: I think it depends on the issue. I think for– if you’re looking at that, the bolted joint itself between the root inserts and the, uh, bolts breaking itself, I, I think they’re doing about quarterly. Now, the pitch bearings inspections are also quarterly. They’re al- they’re, they’re leveraging the drone inspections for the blades, and they’re looking at the pitch bearings to see if they’re cracked, right?

Uh, you guys are doing that too.

Allen Hall: Okay.

Jon Zalar: I think Coraly is doing a good job mitigating the risk, feels like.

Allen Hall: Wow. All right. [00:05:00] Yolanda, looking at pitch bearings, you’ve looked at a lot of drone images in your lifetime. Mm-hmm. How much can you see on drone images on pitch bearings? Can you see cracks and, or y- or do you see grease, which is a really indication that something is wrong in the bearing?

Yolanda Padron: You can see grease. You can see the cracks pretty, pretty well. Yeah. The drone images are, are really high quality. Uh, but you did mention that it’s something that you’re seeing a lot more. Is it because there’s a lot more aging fleets, or is it a problem with a lot of the new turbines that are coming online?

Jon Zalar: I, I think it’s an, I think it’s a more of a fatigue problem, so the aging of the fleet. And also, I think more people are looking at it, right? ‘Cause, like, initially the drones that were looking for blade cracks weren’t looking at pitch bearings, but then pitch bearings started cracking, so now they added that to whatever they buy off the drone companies, right?

Go look at my pitch bearings, for example.

Allen Hall: Hmm.

Jon Zalar: So I, I think it’s a problem of the more you look sometimes, the more you find.

Yolanda Padron: Hmm.

Jon Zalar: Yeah.

Allen Hall: So we [00:06:00] have root insert issues, which are being addressed by a couple of different companies- Yes … uh, uh, with somewhat similar solutions. OEM is offering one right now also.

Jon Zalar: I, I think there’s three solutions. There’s two uptower that are basically looking at ways to go fill the void between the root insert itself and the blade root. Um, and I– there’s another company that’s also more of a downtower solution where they’re actually, like, r- drilling out the root inserts and putting new ones in that are gonna last better, longer.

Allen Hall: Okay. So the drilling out is, would be CNC onsite. Correct.

Jon Zalar: Yeah.

Allen Hall: And they’re based over in Europe. But th- the drilling out is a take the blade down, set it on the ground sort of- Yeah. Right … doing really fine machining on the, on the blade itself. So that, that’s a different, completely different insert that’s going into that-

Jon Zalar: Correct

Allen Hall: new hole or- Yep … clean hole, right? So it’s a, just a, uh, totally different kind of product versus trying to inject [00:07:00] some s- sort of epoxy or resin into the, the void.

Jon Zalar: Right. Yeah. Uh, I mean, you would prefer to do it uptower. It’s gonna cost you less money.

Allen Hall: Sure.

Jon Zalar: But you wanna make sure you do it right, so I think, uh, I do foresee it being a combination of both solutions kinda going forward.

Allen Hall: Is it dependent upon, like, how much damage has been already done, or what the fatigue w- uh, an estimate on what the fatigue life is?

Jon Zalar: I think it’s strictly on measurement perspective right now. So how much gapping you have, um, kinda determines what potential solutions you have.

Allen Hall: So the gaps aren’t big, right?

So the, the gaps I hear are one millimeter is k- kind of sort of start a problem.

Jon Zalar: Mm-hmm.

Allen Hall: Three millimeters is, “I need to be making decisions.”

Jon Zalar: Yeah. So- That, that’s what I’ve heard, too. Yes.

Allen Hall: Three millimeters is about a eighth of an inch.

Jon Zalar: Mm-hmm.

Allen Hall: So it’s not a lot of m-

Jon Zalar: But you can see sunlight through it if you’re s- down there.

Allen Hall: Okay. That’s not… Well, you should see. That’s not

Jon Zalar: good either. Yeah.

Allen Hall: Right. Okay. So in a, in a three millimeter situation then, you’re doing what? [00:08:00]

Jon Zalar: You’re trying to decide if the uptower solutions are something you wanna go try, ’cause they’re still in the trial mode from my understanding or-

Allen Hall: Okay …

Jon Zalar: people are learning a lot.

So I think when you get to that point, you’re calling some of those companies to say, “Hey, I have this issue. I got a couple blades with, you know, .3. Can you guy- you guys wanna come take a look at it, see if your solutions, if you guys wanna go use it or not?” And then I think the ones that get too bad, from my understanding right now, is they’re, they’re replacing the blades.

Allen Hall: So they’re taking the whole blade down.

Jon Zalar: Yes.

Allen Hall: And what’s the thought process in that? Uh, versus drilling out the inserts and putting new inserts in. Is there just a composite degradation that’s happened around those joints that it just puts it at risk or, or you have actually aged the blade much faster than you would otherwise have done?

Jon Zalar: I, I think they aged that particular connection too much. So I, I- Wow … either between the [00:09:00] fatigue or lack of epoxy resin, w- whatever the actual root cause is for that root insert coming out, when it gets that bad, it’s like you’re not gonna be able to inject enough To make it adhere

Allen Hall: You can’t de-age it.

Jon Zalar: Correct.

Allen Hall: Right?

Jon Zalar: Yeah.

Allen Hall: Bring back the youthfulness of the blade. Wow. All right. And we have seen this worldwide. I know in the, in the States you hear about it all the time, but it, this seems to be not a US- Correct … problem.

Jon Zalar: It’s a worldwide problem, yes.

Allen Hall: Okay. So if, if it’s a worldwide problem, are there more solutions on the way?

I know you talked about three of them already.

Jon Zalar: I have not heard of any other ones except those three as of today.

Allen Hall: Wow.

Jon Zalar: There could be other people working on it. I think there should be.

Allen Hall: So, yeah. You would think so, yeah. So we’ll, I guess we’ll eventually hear about it on the podcast. Usually people with technology will contact us.

They might call,

Jon Zalar: yeah. They might call you, they might call you tomorrow.

Allen Hall: Sure, they may. So that leads to sort of a subsequent issue, which I think is getting grouped together. So the [00:10:00] hub crack, pitch bearing crack, root insert pullout issue is also discussed with blade bolts being broken.

Jon Zalar: Correct.

Allen Hall: Are they related or are they separate engineering problems?

Jon Zalar: If you look at them individually, you’d probably come up with some separate answers, but if you combine them all together, you kind of start looking at is there too much loading happening in the leading and trailing edge of the blade? ‘Cause the hub cracks, the root inserts, and the blade bolts, from my understanding, are happening at those two highly loaded areas of the, the blade or that whole rotor connection.

So I mean, I do feel the root cause is probably a little higher loads than anticipated.

Allen Hall: I think everybody’s talked about when they’ve done the injection method and the drilling method, all they’re discussing is leading edge, trailing edge.

Jon Zalar: Yes.

Allen Hall: And how– It’s a question of how many- Correct … are you gonna replace.

So th- [00:11:00] that’s, those are the two highly loaded spots on the bolted connection.

Jon Zalar: Correct.

Allen Hall: And that’s where blade bolts are also breaking or, or the bolts breaking elsewhere around the periphery?

Jon Zalar: I don’t have all the data, but what I had seen, it’s very similar areas.

Allen Hall: So if you don’t pull the insert out, you’re then loading the bolt.

Cr- Right It’s one or the other, right? Right. Yeah. So the, the, the load path is the load path, so it’s coming through the insert into the bolt. Bolt’s carrying it into the pitch bearing. Pitch bearing’s carrying it into the hub.

Jon Zalar: Correct.

Allen Hall: Hub carrying it downtower. So eventually, one of those, uh, links in the chain is- The weakest.

Yeah … is, is the le- is the weakest. What is it about blade bolts that is so dangerous? We hear– we walk onsite to an O&M building, there are signs saying, you know, “Pay attention for loose bolts. Look around on the ground for loose bolts.” We’re gonna– and as electrical engineer, like, “Whoa.” Bolts should not be falling out of this tower.

What i- what is that sort of sequence where a [00:12:00] bolt would escape from the nacelle?

Jon Zalar: So let’s just use one bolt. One bolt breaks, falls in the hub, bouncing around, doing some– potentially doing some damage inside the hub. And ’cause these turbines, you don’t need to go out there every day ’cause they do run pretty good, right?

Right. You just do your regular maintenance. And if you don’t really know about that, ’cause, like, it bounces around for a while, then it usually gets, like, lodged behind a, uh, either center box or pitch cabinet or actually in the front sometimes. Kinda don’t know it happened. But, you know, frees itself up, keeps bouncing around, it, it could escape through the hatch covers ’cause, you know, people have to get into the hub anyway.

And I’m sure a lot of people listening here that have sites, like, you know, probably found some bolts laying on the ground, which is a little scary.

Allen Hall: Right. So is, is the busting the hatch opening levers? I know there, there’s a couple different ways to get into that hatch. Yeah. But, uh, is it just completely busting the hatch?

Yeah. So it’s– [00:13:00] okay. So you see a– so if you see a loose hatch panel, you have an issue. You probably gotta be careful about coming up on that turbine?

Jon Zalar: Potentially. A lot, a lot of hatches are, you know, not always maintained well.

Allen Hall: Right. I’ve seen them, I’ve seen loose ones, yeah.

Jon Zalar: Yeah.

Allen Hall: Okay. So that, that would be a sign that– but though if, if you’re approaching a turbine, one look on the ground.

And Yolando, you, you’ve seen a lot of turbines. So are you, are we looking on the ground and seeing what’s around the turbine before we approach the turbine now? Yeah. Just, just a sanity check?

Yolanda Padron: Yeah. Be aware also of what’s happening on site, right? Because if it’s some- if it’s a problem on site, you need to be extra careful when you’re approaching any turbine there.

Uh, is it something that people maybe should start thinking about implementing, like, a sensors earlier on than when they’re seeing the issue actually happen?

Jon Zalar: Yeah. I, I, I think that’s a potential, ’cause it, the quicker you catch it, the less damage you’re gonna do, and it also reduce the risk of [00:14:00] it, um, falling out of the hub And I’ve worked with a couple of my, uh, customers for some, like, potential ways to detect it.

Still kind of trialing it right now. But I, I do think there’s gonna be some benefit from a safety reduction, but also from a strictly a damage. ‘Cause, like, you get a couple bolts bouncing around there, and you bang up some cabinets or some pitch motors, that’s expensive and hard to go fix.

Yolanda Padron: Yeah, we were talking about it earlier too.

Like, it goes down, it can hit a transformer, it can hit, like, a truck or someone.

Jon Zalar: Chance of it hitting someone. Yeah. I mean, I don’t care what hard hat you have on, it’s not gonna do anything.

Yolanda Padron: Yeah.

Allen Hall: So what kind of sensor should you be putting onto the turbine if you don’t have access to the SCADA data or you don’t know what the correct algorithm is to suss out there’s something wrong up there?

But a, a bolt breaking is not gonna be something that a SCADA would even pick up, I don’t think. One bolt out of the whole- Yeah. No.

Jon Zalar: No way. Okay. I mean, there’s a– I think there’s, like, [00:15:00]one company looking at more of a, like, mechanical way to, like, prevent the bolt from coming out. I forgot the name of it.

Allen Hall: Okay.

Jon Zalar: Um, and then what I was looking at was more of a, like, you know, microphone type detection to kind of listen for that.

Allen Hall: It would make a lot of noise.

Jon Zalar: Yeah. It seems like it works. It, um, yeah, still more development needed on my end.

Allen Hall: So- The engineer in me was, is saying, “Why are we not putting strain gauges on bolts?”

I picked on the leading and the trailing. It’s like right dead center there to look at, even if it’s just two strain gauge bolts to see what the loads are.

Jon Zalar: So like there are s- there are bolts that are, or that are made with the strain gauges built in that you can use to go, you know, monitor that. But you also need to understand like what was the design intent.

So unless you’re working with the OEM, you don’t really know what you’re seeing is good or bad. You just say, “Oh-

Allen Hall: You just see a number.

Jon Zalar: Yeah. Right. I mean like, and if you install, I don’t know, four, you’d be like, “All right. Leading and trailing edge are higher [00:16:00] than the other two.” Well, yeah, it’s supposed to be, but like is a 10% difference expected or not expected?

Allen Hall: Is that something where if you’re, especially if you’re in a full service agreement, and a lot of these turbines are- Yeah … for the first couple of years, if you were to do that, it’s something you would just say to the OEM, “Hey, this is, these are the loads we’re seeing from the strain gauges on these bolts.

Does this make sense to you?” Or, or would an OEM just not even respond to that kind of inquiry?

Jon Zalar: I mean, I think it’s all about relationship with the OEM. I, I, I think

Allen Hall: it- I think they would wanna know.

Jon Zalar: I have a feeling they probably are looking.

Allen Hall: Okay.

Jon Zalar: I mean, ’cause I mean they have the test turbines too that they probab- that, that I know they have instrumented heavily.

Allen Hall: Yeah. So they, they’re probably getting at least some feedback. Th- that’s the problem. Yeah. And you worked on the other side, right? I have. So you worked for an OEM doing the RTAs. The first problem is you don’t have data, so now you gotta go get the data.

Jon Zalar: Correct.

Allen Hall: And that data is not available tomorrow. No.

‘Cause you’re gonna have to go run some sort of design of experiment to go figure out if [00:17:00] there is even a true problem or even what the root causes could be.

Jon Zalar: And it, and it’s expensive to go instrument a blade and get the data back at the right speed and connected to the turbine data. I mean, I rem- I, I used to say it’s about like 300 to 500,000 to go put a couple gauges on a blade just with all the equipment you need to get the data correct.

Allen Hall: To get the right data.

Jon Zalar: Get the right data at the right frequency connected to the controller. It’s, it’s very expensive.

Allen Hall: Wow. Okay. Yeah. I, I don’t, I don’t see a lot of operators doing that.

Jon Zalar: And especially connecting it to the operating data, right? So like if you go put a strain gauge and I don’t know, you’re curtailed, you’re only making, I don’t know, a megawatt- Doesn’t matter.

And if you don’t know what the turbine’s doing and you’re looking at this, like, strain gauge data, it’s really hard to correlate anything.

Allen Hall: So you need a full suite of data. Yeah. That includes weather data- Yeah … at some level, right? Gust winds and- Oh,

Jon Zalar: yeah …

Allen Hall: average wind speed. You need the anemometer. You need which, which way [00:18:00] the n- cell’s pointing.

Y- uh, you would need a lot of information- And what the controller’s- … to even suss it out …

Jon Zalar: and what the controller’s doing, right? Right. ‘Cause, like, every turbine, the controller’s trying to, like, you know, balance the rotor the whole time. It’s trying to, you know, micro pitch depending on what the winds are doing.

And if you don’t know what all that stuff’s doing, like, it’s really hard to correlate a strain gauge measurement to is that bad or not.

Allen Hall: It’s a complicated problem.

Jon Zalar: Yes. That’s why RCAs take, you know, a long time, and they’re not done in two weeks.

Allen Hall: No, they’re done in a year.

Jon Zalar: Yeah.

Allen Hall: Typically, or longer. So what should an operator be thinking about now?

If, if we s- get our drone images back, we’re scanning through them like, “Oh, there’s a crack” What am I doing next besides calling you and connecting to your LinkedIn page?

Jon Zalar: So right now with the pitch bearing crack, um, some of the OEMs are providing stiffener plates to put over the crack and try to run it.

Allen Hall: So that’s a doubler plate, basically. A double plate. Doubler

Jon Zalar: plate, yes. [00:19:00]

Allen Hall: Yeah. Okay. So even in a, in a crack scenario, that pitch bearing, if given mechanical support, can run like that?

Jon Zalar: That’s my understanding, yes. That, that potentially could run for some period of time. I don’t know if it’ll make it 20 years or not, but it’ll buy you time for sure.

Allen Hall: Does that involve a crane to do that work or is that just… My recollection, that was in pieces, like there, it’s not a ring, it’s a, a couple of pieces that you’d be able to bolt on without taking the-

Jon Zalar: No, it’s a- … blade down … it’s a, it’s a single piece that-

Allen Hall: It’s like a single casting kind of thing.

Jon Zalar: Right. And I, I think you need some like small crane, like a jig crane or one of those-

Allen Hall: Just to support the blade while you do it?

Jon Zalar: And to go put it in, right. Okay. Yeah, I don’t think, you’re not taking the blade off. You’re not taking the

Allen Hall: blade down.

Jon Zalar: Correct. Yeah. It’s, it’s done with the blade up there.

Allen Hall: Okay.

Jon Zalar: You’re putting new, putting longer studs in and putting the plate on.

Allen Hall: So first step is let’s get the joint reinforced. Right.

That’s the easy first step.

Jon Zalar: Right. Although there has been some cases where since [00:20:00]you’ve put that stiffener plate on, the loads get spread out to the end of the plate, and then you- Sure … you could see cracks there.

Allen Hall: Okay. All right. So the loads- It, that- … have to go somewhere …

Jon Zalar: loads have to go somewhere. That’s, that is a bottom line.

Allen Hall: All right. So you’re just changing where the load path is, so you have to be cognizant of that. Okay. Sure. Fine. But if you have, uh, especially in the United States, you don’t have 10 of these turbines, you have 50, 100- 100 … 200, 300 of these things, or thousands as it, as it turns out. Are there simple solutions that can be applied to, just to give me a sense, like that turbine’s having a problem, but the one next to it’s not, and, and just, just from a maintenance spin standpoint where I’m not just blanketing everything and trying to do everything to all these turbines at once, how do I, how do I manage this?

Jon Zalar: I, I think it’s like being very observant. So like, you know, making sure you’re looking at the pitch bearings from the drone images, right? Um, also talking [00:21:00] to your maintenance people like, “Hey, are, are you finding a bunch of broken bolts? Like, what positions?” Like, you know, if I was back at the OEM, I would like to have as much data as possible on this issue.

Like how many bolts are, when did you find them, what positions? A lot of times we, when I was there, like we would not get all that information, so it’s like really hard to run an RCA without that information.

Allen Hall: Sure. Yeah, where did this bolt break in the ring?

Jon Zalar: Right.

Allen Hall: Could tell you a lot. Is it just a b- bad lot of bolts, or is it something more load related?

Jon Zalar: Correct.

Allen Hall: Wow. Okay.

Yolanda Padron: Yeah, I think that’s a really good point, too, to make sure that you’re connected with like every stage of the operations. ‘Cause I know that everybody’s obviously really, really busy on a wind farm, but it’s really common for like an engineer to have certain data and the site team to just be running around and having a lot of data, but maybe they don’t realize that, oh, it’s important to know how many bolts per tower are coming down.

Jon Zalar: Correct. Yeah

Allen Hall: That’s a lot of work

Jon Zalar: It definitely-

Allen Hall: It’s a tremendous effort if you’re gonna [00:22:00] go after this problem and, and solve it RCS

Jon Zalar: are hard. They

Allen Hall: are. Yeah. All of it. Yeah. Machines are complicated today. There’s a lot of computer-driven s- things about them, and then you have these loading issues, and you have composite materials.

Th- there’s just, y-

Jon Zalar: you got to get- It’s a very complex

Allen Hall: It’s a machine, right? Yeah. It’s a complex machine. So how do people reach out to… You’re, you’re the head of IWTG, which is based in South Carolina, but you do consulting worldwide. Yes. And, and you are a huge resource because you understand the complexities of these problems.

How do people get ahold of you and, and get something started if they have a, a, a blade bolt issue or an insert issue or a cracked pitch bearing? Where do they start?

Jon Zalar: They can send me an email, jzalar@iwtgconsulting.com.

Allen Hall: Okay. And you have a great LinkedIn page, so you can connect with you on LinkedIn.

Jon Zalar: Yes.

Yeah, I have one

Allen Hall: of those. Yes. Or you could just come to WOMA in [00:23:00]2027. Yeah. You can. You can meet John there and, and arrange everything there. So John, it’s great to see you, and thank you for coming up. We, uh, we’re recording this at the world headquarters of Weather Guard Lightning Tech, and, uh, John just lives down the street in, in, in US terms.

Yeah. So it’s, it’s great to have John come and visit us up here in North Carolina. So John, thank you so much for joining us.

Jon Zalar: Thanks for having me. Appreciate it.

IWTG Consulting on Pitch Bearing Cracks, Loose Root Inserts

Renewable Energy

The Divided States of America

Published

2 days ago

August 5, 2026

Alice Rush

Trump’s (fairly successful) attempts to divide America are just a means to the end of staying in power so as to be able to continue to loot the U.S. treasury.

At this point, there are three essential factions in the United States:

A small number of extremely powerful billionaires
The MAGA base of white nationalist / hateful morons who believe that only Trump can save us from communism, racial impurity, and godlessness
Decent, educated people