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Vestas Buys TPI Assets, GE Supply Chain in Doubt

Allen, Joel, Rosemary, and Yolanda break down the TPI Composites bankruptcy fallout. Vestas is acquiring TPI’s Mexico and India operations while a UAE company picks up the Turkish factories. That leaves GE in a tough spot with no clear path to blade manufacturing. Plus the crew discusses blade scarcity, FSA availability floors, and whether a new blade manufacturer could emerge.

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!

Allen Hall: [00:00:00] Welcome to the Uptime Wind Energy Podcast. I’m your host, Allen Hall. I’ve got Yolanda Padron and Joel Saxum in Texas. And Rosemary Barnes is back from her long Vacation in Australia and TPI. Composites is big in the news this week, everybody, because they’re in bankruptcy hearings and they are selling off parts of the business.

Vestas is, at least according to News Reports positioned to acquire. A couple of the LLCs down in Mexico. So there’s uh, two of them, TPI in Mexico, five LLC, and TPI in Mexico, six LLC. There are other LLCs, of course involved with this down in Mexico. So they’re buying, not sure exactly what the assets are, but probably a couple of the factories in which their blades were being manufactured in.

Uh, this. Is occurring because Vestas stepped in. They were trying to have an auction and Vestas stepped forward and just ended up buying these two LLCs. [00:01:00] Other things that are happening here, Joel, is that, uh, TPI evidently sold their Turkish division. Do you recall to who they sold? That, uh, part of the

Joel Saxum: business too, two companies involved in that, that were TPI Turkey, uh, and that was bought by a company called XCS composites.

Uh, and they are out of the United Arab Emirates, so I believe they’re either going to be Abu Dhabi or Dubai based. Uh, but they took over the tube wind blade manufacturing plants in Isme, uh, also a field service and inspection repair business. And around 2,700 employees, uh, from the Turkish operation. So that happened just, just after, I mean, it was a couple weeks after the bankruptcy claim, uh, went through here in August, uh, in the States.

So it went August bankruptcy for TPI, September, all the Turkish operations were bought and now we’ve got Vestas swooping in and uh, taking a bunch of the Mexican operations.

Allen Hall: Right. And [00:02:00] Vestas is also taking TPI composites India. Which is a part of the business that is not in bankruptcy, uh, that’s a, a separate business, a separate, basically LLC incorporation Over in India, the Vestus is going to acquire, so they’re gonna acquire three separate things in this transaction.

The question everybody’s asking today after seeing this Vestus move is, what is GE doing? Because, uh, GE Renova has a lot of blades manufactured by TPI down in Mexico. No word on that. And you would think if, if TPI is auctioning off assets that GE renova would be at the front of the line, but that’s not what we’re hearing on the ground.

Joel Saxum: Yeah, I mean it’s, the interesting part of this thing is for Vestas, TPI was about 35% of their blade capacity for manufacturing in 2024. If their 30, if, if Vestas was 35%, then GE had to be 50%. There [00:03:00] demand 60. So Vesta is making a really smart move here by basically saying, uh, we’ve gotta lock down our supply chain for blades.

We gotta do something. So we need to do this. GE is gonna be the odd man out because, I mean, I think it would be a, a cold day in Denmark if Vestas was gonna manufacture blades for ge.

Allen Hall: Will the sale price that Vest has paid for this asset show up in the bankruptcy? Hearings or disclosures? I think that it would, I haven’t seen it yet, but eventually it’ll, it must show up, right?

All, all the bankruptcy hearings and transactions are, they have an overseer essentially, what happens to, so TPI can’t purchase or sell anything without an, um, getting approved by the courts, so that’ll eventually be disclosed. Uh, the Turkish sale will be, I would assume, would be disclosed. Also really curious to see what the asset value.

Was for those factories.

Joel Saxum: So the Turkish sale is actually public knowledge right now, and [00:04:00] that is, lemme get the number here to make sure I get it right. 92.9 million Euros. Uh, but of, of course TPI laden with a bunch of non-convertible and convertible debt. So a ton of that money went right down to debt.

Uh, but to be able to purchase that. They had to assu, uh, XCS composites in Turkey, had to assume debt as is, uh, under the bankruptcy kind of proceedings. So I would assume that Vestas is gonna have to do the same thing, is assume the debt as is to take these assets over and, uh, and assets. We don’t know what it is yet.

We don’t know if it’s employees, if it’s operations, if it’s ip, if it’s just factories. We don’t know what’s all involved in it. Um, but like you said, because. TPI being a publicly traded company in the United States, they have to file all this stuff with SEC.

Allen Hall: Well, they’ll, they’re be delisted off of. Was it, they were

Joel Saxum: in Nasdaq?

Is that where they were listed? The India stuff that could be private. You may ne we may not ever hear about what happened. Valuation there.

Allen Hall: Okay, so what is the, the [00:05:00] future then for wind blade production? ’cause TPI was doing a substantial part of it for the world. I mean, outside of China, it’s TPI. And LM a little bit, right?

LM didn’t have the capacity, I don’t think TPI that TPI does or did. It puts

Joel Saxum: specifically GE in a tight spot, right? Because GEs, most of their blades were if it was built to spec or built to print. Built to spec was designed, uh, by LM and built by lm. But now LM as we have seen in the past months year, has basically relinquished themselves of all of their good engineering, uh, and ability to iterate going forward.

So that’s kind of like dwindling to an end. TPI also a big side of who makes blades for ge if Vestas is gonna own the majority of their capacity, Vestas isn’t gonna make blades for ge. So GEs going to be looking at what can we, what can we still build with lm? And then you have the kind of the, the odd ducks there.

You have the Aris, [00:06:00] you have the MFG, um, I mean Sonoma is out there. This XCS factory is there still in Turkey. Um, you may see some new players pop up. Uh, I don’t know. Um, we’ll see. I mean, uh, Rosemary, what’s, what’s your take? Uh, you guys are starting to really ramp up down in Australia right now and are gonna be in the need of blades in general with this kind of shakeup.

Rosemary Barnes: What do we say? My main concern is. Around the service of the blades that we’ve already got. Um, and when I talk to people that I know at LM or XLM, my understanding is that those parts of the organization are still mostly intact. So I actually don’t expect any big changes there. Not to say that the status quo.

Good enough. It’s not like, like every single OEM whose, um, FSAs that I work with, uh, support is never good enough. But, um, [00:07:00] it shouldn’t get any worse anyway. And then for upcoming projects, yeah, I, I don’t know. I mean, I guess it’s gonna be on a case by case basis. Uh, I mean, it always was when you got a new, a new project, you need a whole bunch of blades.

It was always a matter of figuring out which factory they were going to come from and if they had capacity. It’ll be the same. It’s just that then instead of, you know, half a dozen factories to choose from, there’s like, what, like one or two. So, um, yeah, I, that’s, that’s my expectation of what’s gonna happen.

I presumably ge aren’t selling turbines that they have no capability to make blades for. Um, so I, I guess they’re just gonna have a lot less sales. That’s the only real way I can make it work.

Allen Hall: GE has never run a Blade factory by themselves. They’ve always had LM or somebody do it, uh, down in Brazil or TPI in Mexico or wherever.

Uh, are we thinking that GE Renova is not gonna run a Blade Factory? Is that the thought, or, or is [00:08:00] that’s not in the cards either.

Rosemary Barnes: I don’t think it’s that easy to just, just start running a Blade Factory. I mean, I know that GE had blade design capabilities. I used to design the blades that TPI would make.

So, um, that part of it. Sure. Um, they can, they can still do that, but it’s not, yeah, it’s, it’s not like you just buy a Blade factory and like press start on the factory and then the, you know, production line just starts off and blades come out the other end. Like there is a lot of a, a lot of knowhow needed if that was something that they wanted to do.

That should have been what they started doing from day one after they bought lm. You know, that was the opportunity that they had to become, you know, a Blade factory owner. They could have started to, you know, make, um, have GE. Take up full ownership of the, the blade factories and how that all worked. But instead, they kept on operating like pretty autonomously without that many [00:09:00] changes at the factory level.

Like if they were to now say, oh, you know, hey, it’s, uh, we really want to. Have our own blade factories and make blades. It’s just like, what the hell were you doing for the last, was it like seven years or something? Like you, you could easily have done what? And now you haven’t made it as hard for yourselves as possible.

So like I’m not ruling out that that’s what they’re gonna try and do, because like I said, I don’t think it’s been like executed well, but. My God, it’s like even stupid of the whole situation. If that’s where we end up with them now scrambling to build from scratch blade, um, manufacturing capability because there’s

Yolanda Padron: already a blade scarcity, right?

Like at least in the us I don’t know if you guys are seeing it in, in Australia as well, but there’s a blade scarcity for these GE blades, right? So you’re, they kind of put themselves in an even more tough spot by just now. You, you don’t have access to a lot of these TPI factories written in theory. From what we’re seeing.

You mean to get like replacement blades? Yeah. So like for, for issues? Yeah. New [00:10:00] construction issues under FSA, that,

Rosemary Barnes: yeah. I mean, we’ve always waited a, a long time for new blades. Like it’s never great. If you need a new blade, you’re always gonna be waiting six months, maybe 12 months. So that’s always been the case, but now we are seeing delays of that.

Maybe, maybe sometimes longer, but also it’s like, oh well. We can’t replace, like, for like, you’re gonna be getting a, a different kind of blade. Um, that will work. Um, but you know, so that is fine, except for that, that means you can’t do a single blade replacement anymore. Now, what should have been a single blade replacement might be a full set replacement.

And so it does start to really, um, yeah. Mess things up and like, yeah, it’s covered by the FSA, like that’s on them to buy the three blades instead of one, but. It does matter because, you know, if they’re losing money on, um, managing your wind farm, then it, it is gonna lead to worse outcomes for you because, you know, they’re gonna have to skimp and scrape where they [00:11:00] can to, you know, like, um, minimize their losses.

So I, I don’t think it’s, it’s, it’s

Yolanda Padron: not great. Yeah. And if you’re running a wind farm, you have other stakeholders too, right? It’s not like you’re running it just for yourself. So having all that downtime from towers down for a year. Because you can’t get blades on your site. Like it’s just really not great.

Rosemary Barnes: Yeah, and I mean, there’s flaws on there. Like they’ve got an availability guarantee. Then, you know, below that they do have to, um, pay for that, those losses. But there’s a flaw on that. So once you know, you, you blast through the floor of your availability, then you know, that is on the owner. Now it’s not on the, um, service provider.

So it’s definitely. Something that, yeah, there’s lots of things where you might think, oh, I don’t have to worry about my blades ’cause I’ve got an F, SA, but you know, that’s just one example where, okay, you will, you will start worrying if they, they yeah. Fall through the floor of their availability guarantee.

Joel Saxum: Two questions that pop up in my mind from this one, the first one, the first one is [00:12:00] directly from Alan. You and I did a webinar, we do so many of ’em yesterday, and it was about, it was in the nor in North America, ferc, so. They have new icing readiness, uh, reporting you, so, so basically like if you’re on the, if you’re connected to the grid, you’re a wind farm or solar farm and you have an icing event, you need to explain to them why you had an outage, um, and why, what you’re doing about it.

Or if you’re not doing something about it, you have to justify it. You have to do all these things to say. Hey, some electrons weren’t flowing into the grid. There’s certain levels. It’s much more complicated than this, but electrons weren’t flowing into the grid because of an issue. We now have to report to FERC about this.

So is there a stage when a FERC or uh, some other regulatory agency starts stepping into the wind industry saying like, someone’s gotta secure a supply chain here. ’cause they’re already looking at things when electrons are on the grid. Someone’s got a secure supply chain here so we can ensure that [00:13:00]these electrons are gonna get on the grid.

Could, can something like that happen or was, I mean, I mean, of course that’s, to me, in my opinion, that’s a lot of governmental overreach, but could we see that start to come down the line like, Hey, we see from an agency’s perspective, we see some problems here. What are you doing to shore this up?

Allen Hall: Oh, totally.

Right. I, I think the industry in general has an issue. This is not an OEM specific problem. At the minute, if this is a industry-wide problem, there seems to be more dispersed. Manufacturers are gonna be popping up. And when we were in Scotland, uh, we learned a lot more about that. Right, Joel? So the industry has more diversification.

I, I, here’s, here’s my concern at the minute, so. For all these blade manufacturers that we would otherwise know off the top of our heads. Right. Uh, lm, TPI, uh, Aris down in Brazil. The Vestus manufacturing facilities, the Siemens manufacturing [00:14:00] facilities. Right. You, you’re, you’re in this place where. You know, everybody’s kind of connected up the chain, uh, to a large OEM and all this made sense.

You know, who was rebuilding your blades next year and the year down, two years down the road. Today you don’t, so you don’t know who owns that company. You don’t know how the manager’s gonna respond. Are you negotiating with a company that you can trust’s? Gonna be there in two or three years because you may have to wait that long to get blades delivered.

I don’t know. I think that it, it put a lot of investment, uh, companies in a real quandary of whether they wanna proceed or not based upon the, what they is, what they would perceive to be the stability of these blade companies. That’s what I would think. I, I, Vestas is probably the best suited at the minute, besides Siemens.

You know, Vestas is probably best suited to have the most perceived reliability capability. Control,

Joel Saxum: but they have their own [00:15:00] blade factories already, right? So if they buy the TPI ones, they’re just kind of like they can do some copy pasting to get the the things in place. And to be honest with you, Vesta right now makes the best blades out there, in my opinion, least amount of serial defects.

Remove one, remove one big issue from the last couple

Allen Hall: years. But I think all the OEMs have problems. It’s a question of how widely known those problems are. I, I don’t think it’s that. I think the, the, the. When you talk to operators and, and they do a lot of shopping on wind turbines, what they’ll tell you generally is vestus is about somewhere around 20% higher in terms of cost to purchase a turbine from them.

And Vestus is gonna put on a, a full service agreement of some sort that’s gonna run roughly 30 years. So there’s a lot of overhead that comes with buying a, a Vestas turbine. Yes. You, you get the quality. Yes. You get the name. Yes, you get the full service agreement, which you may or [00:16:00] may not really want over time.

Uh, that’s a huge decision. But as pieces are being removed from the board of what you can possibly do, there’s it, it’s getting narrow or narrow by the minute. So it, it’s either a vestus in, in today’s world, like right today, I think we should talk about this, but it’s either Vestus or Nordic. Those are the two that are being decided upon.

Mostly by a lot of the operators today.

Joel Saxum: That’s true. We’re, and we just saw Nordex, just inked a one gigawatt deal with Alliant Energy, uh, just last week. And that’s new because Alliant has traditionally been a GE buyer. Right. They have five or six ge, two X wind farms in the, in the middle of the United States, and now they’ve secured a deal with Nordex for a gigawatt.

Same thing we saw up at Hydro Quebec. Right. Vestas and Nordex are the only ones that qualify for that big, and that’s supposed to be like a 10 gigawatt tender over time. Right. But the, so it brings me to my, I guess my other question, I was thinking about this be [00:17:00] after the FERC thing was, does do, will we see a new blade manufacturer

Allen Hall: pop

Joel Saxum: up?

Allen Hall: No, I don’t think you see a new one. I think you see an acquisition, uh, a transfer of assets to somebody else to run it, but that is really insecure. I, I always think when you’re buying distressed assets and you think you’re gonna run it better than the next guy that. Is rare in industry to do that. Think about the times you’ve seen that happen and it doesn’t work out probably more than 75% of the time.

It doesn’t work out. It lasts a year or two or three, and they had the same problems they had when the original company was there. You got the same people inside the same building, building the same product, what do you think is magically gonna change? Right? You have this culture problem or a a already established culture, you’re not likely to change that unless you’re willing to fire, you know, a third of the staff to, to make changes.

I don’t see anybody here doing that at the minute because. Finding wind blade technicians, manufacturing people is [00:18:00] extremely hard to do, to find people that are qualified. So you don’t wanna lose them.

Joel Saxum: So this is why I say, this is why I pose the question, because in my mind, in in recent wind history, the perfect storm for a new blade manufacturer is happening right now.

And the, and the why I say this is there is good engineers on the streets available. Now washing them of their old bad habits and the cultures and those things, that’s a monumental task. That’s not possible.

Allen Hall: Rosemary worked at a large blade manufacturer and it has a culture to it. That culture really didn’t change even after they were acquired by a large OEM.

The culture basically

Rosemary Barnes: remained, they bizarrely didn’t try and change that culture, like they didn’t try to make it a GE company so that it wasn’t dur, it was wasn’t durable. You know, they, they could have. Used that as a shortcut to gaining, um, blade manufacturing capabilities and they didn’t. And that was a, I think it was a choice.

I don’t think it’s an inevitability. It’s never easy to go in and change a, a culture, [00:19:00] but it is possible to at least, you know, get parts of it. Um, the, the knowledge should, you should be able to transfer and then get rid of the old culture once you’ve done that, you know, like, uh. Yeah, like you, you bring it in and suck out all the good stuff and spit out the rest.

They didn’t do that.

Joel Saxum: The opportunity here is, is that you’ve got a, you’ve got people, there’s gonna be a shortage of blade capacity, right? So if you are, if you are going to start up a blade manufacturing facility, you, if you’re clever enough, you may be able to get the backlog of a bunch of orders to get running without having to try to figure it out as you go.

Yolanda Padron: I feel like I’d almost make the case that like the blade repair versus replace gap or the business cases is getting larger and larger now, right? So I feel like there’s more of a market for like some sort of holistic maintenance team to come in and say, Hey, I know this OEM hasn’t been taking care of your blades really well, but here are these retrofits that have proven to be [00:20:00]to work on your blades and solve these issues and we’ll get you up and running.

Rosemary Barnes: We are seeing more and more of of that. The thing that makes it hard for that to be a really great solution is that they don’t have the information that they need. They have to reverse engineer everything, and that is. Very challenging because like you can reverse engineer what a blade is, but it doesn’t mean that, you know, um, exactly like, because a, the blade that you end up with is not an optimized blade in every location, right?

There’s some parts that are overbuilt and um, sometimes some parts that are underbuilt, which gives you, um, you know, serial issues. But, so reverse engineering isn’t necessarily gonna make it safe, and so that does mean that yeah, like anyone coming in with a really big, significant repair that doesn’t go through the OEM, it’s a, it’s a risk.

It, it’s always a risk that they have, you know, like there’s certain repairs where you can reverse engineer enough to know that you’re safe. But any really big [00:21:00] one, um, or anything that involves multiple components, um, is. Is a bit of a gamble if it doesn’t go through the OEM.

Joel Saxum: No, but so between, I guess between the comments there, Yolanda and Rosemary, are we then entering the the golden age of opportunity for in independent engineering experts?

Rosemary Barnes: I believe so. I’m staking, staking my whole business on it.

Allen Hall: I think you have to be careful here, everybody, because the problem is gonna be Chinese blade manufacturers. If you wanna try to establish yourself as a blade manufacturer and you’re taking an existing factory, say, say you bought a TPI factory in Turkey or somewhere, and you thought, okay, I, I know how to do this better than everybody else.

That could be totally true. However, the OEMs are not committed to buying blades from you and your competition isn’t the Blade Factory in Denmark or in Colorado or North Dakota, or in Mexico or Canada, Spain, wherever your competition is when, [00:22:00] uh, the OEM says, I can buy these blades for 20 to 30% less money in China, and that’s what you’re gonna be held as, as a standard.

That is what’s gonna kill most of these things with a 25% tariff on top. Right? Exactly. But still they’re still bringing

Joel Saxum: blades in. That’s why I’m saying a local blade manufacturer,

Rosemary Barnes: I think it’s less the case. That everyone thinks about China, although maybe a little bit unconventional opinion a about China, they certainly can manufacture blades with, uh, as good a quality as anyone.

I mean, obviously all of the, um, Danish, uh, American manufacturers have factories in China that are putting out excellent quality blades. So I’m not trying to say that they dunno how to make a good blade, but with their. New designs, you know, and the really cheap ones. There’s a couple of, um, there’s a couple of reasons for that that mean that I don’t think that it just slots really well into just replacing all of the rest of the world’s, um, wind turbines.

The first is that there are a lot of [00:23:00] subsidies in China. Surely there can only continue so long as their economy is strong. You know, like if their economy slows down, like to what extent are they gonna be able to continue to, um, continue with these subsidies? I would be a little bit nervous about buying an asset that I needed support for the next 30 years from a company like.

That ecosystem. Then the other thing is that, um, that development, they move really fast because they take some shortcuts. There’s no judgment there. In fact, from a develop product development point of view, that is absolutely the best way to move really fast and get to a really good product fast. It will be pervasive all the way through every aspect of it.

Um, non-Chinese companies are just working to a different standard, which slows them down. But also means that along the way, like I would be much happier with a half developed, um, product from a non-Chinese manufacturer than a half developed product from a Chinese manufacturer. The end point, like if China can keep on going long enough with this, [00:24:00] you know, like just really move fast, make bold decisions, learn everything you can.

If they can continue with that long enough to get to a mature product, then absolutely they will just smash the rest of the world to pieces. So for me, it’s a matter of, um, does their economy stay strong enough to support that level of, uh, competition?

Allen Hall: Well, no, that’s a really good take. It’s an engineering take, and I think the decision is made in the procurement offices of the OEMs and when they start looking at the numbers and trying to determine profitability.

That extra 20% savings they can get on blades made in China comes into play quite often. This is why they’re having such a large discussion about Chinese manufacturers coming into the eu. More broadly is the the Vestas and the Siemens CAAs and even the GE Re Novas. No, it’s big time trouble because the cost structure is lower.

It just is, and I. [00:25:00] As much as I would love to see Vestas and Siemens and GE Renova compete on a global stage, they can’t at the moment. That’s evident. I don’t think it’s a great time to be opening any new Blade Factory. If you’re not an already established company, it’s gonna be extremely difficult. Wind Energy O and M Australia is back February 17th and 18th at Melbourne’s Pullman on the park.

Which is a great hotel. We built this year’s agenda directly from the conversations we’ve had in 2025 and tackling serial defects, insurance pressures, blade repairs, and the operational challenges that keeps everybody up at night around the world. So we have two days of technical sessions, interactive roundtables and networking that actually moves the industry for.

Forward. And if you’re interested in attending this, you need to go to WMA 2020 six.com. It’s WOMA 2020 six.com. Rosemary, a lot of, uh, great events gonna happen at. W 2026. Why don’t [00:26:00] you give us a little highlight. Parlet iss gonna be there.

Rosemary Barnes: Parlow is gonna be there. I mean, a highlight for me is always getting together with the, the group.

And also, I mean, I just really love the size of the event that uh, every single person who’s there is interested in the same types of things that you are interested in. So the highlight for me is, uh, the conversations that I don’t know that I’m gonna have yet. So looking forward to that. But we are also.

Making sure that we’ve got a really great program. We’ve got a good mix of Australian speakers and a few people bringing international experience as well. There’s also a few side events that are being organized, like there’s an operators only forum, which unfortunately none of us will be able to enter because we’re not operators, but that is gonna be really great for.

For all of them to be able to get together and talk about issues that they have with no, nobody else in the room. So if, if you are an operator and you’re not aware of that, then get in touch and we’ll pass on your details to make sure you can join. Um, yeah, and people just, you know, [00:27:00] taking the opportunities to catch up with clients, you know, for paddle load.

Most or all of our clients are, are gonna be there. So it is nice to get off Zoom and um, yeah, actually sit face to face and discuss things in person. So definitely encourage everyone to try and arrange those sorts of things while they’re there.

Joel Saxum: You know, one of the things I think is really important about this event is that, uh, we’re, we’re continuing the conversation from last year, but a piece of feedback last year was.

Fantastic job with the conversation and helping people with o and m issues and giving us things we can take back and actually integrate into our operations right away. But then a week or two or three weeks after the event, we had those things, but the conversation stopped. So this year we’re putting some things in place.

One of ’em being like Rosemary was talking about the private operator forum. Where there’s a couple of operators that have actually taken the reins with this thing and they wanna put this, they wanna make this group a thing where they’re want to have quarterly meetings and they want to continue this conversation and knowledge share and boost that whole Australian market in the wind [00:28:00]side up right?

Rising waters floats all boats, and we’re gonna really take that to the next level this year at

Allen Hall: WMA down in Melbourne. That’s why I need a register now at Wilma 2020 six.com because the industry needs solutions. Speeches. That wraps up another episode of the Uptime Wind Energy Podcast. Thanks for joining us.

We appreciate all the feedback and support we received from the wind industry. If today’s discussion sparked any questions or ideas, we’d love to hear from you. Just reach out to us on LinkedIn and please don’t forget to subscribe so you’d never miss an episode. For Joel Rosemary and Yolanda, I’m Allen Hall.

We’ll catch you next week on the Uptime Wind Energy Podcast.

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Vineyard Wind Battles GE Vernova, UK Funds Blade Innovation

Fraunhofer studies uptower carbon blade repairs, Vineyard Wind’s fight with GE Vernova deepens, the UK backs offshore innovation, and a 26-year Horns Rev study tracks how birds adapt to turbines.

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 StrikeTape.  Protecting thousands of wind turbines from lightning damage worldwide. Visit striketape.com. And now your hosts.

Allen Hall: Welcome to the Uptime Wind Energy podcast. I’m your host, Allen Hall. I’m here with Rosemary Barnes, Yolanda Padron, and Matthew Stead. Fraunhofer has published peer-reviewed feasibility research in wind energy science. And Rosemary, I don’t know if you read wind energy science, but there’s a lot of good information there about wind turbines and mechanical aspects.

Not much on the electrical side, but a lot about mechanical. Uh, in, in, in wind energy science, uh, they had a discussion or an article about repairing damaged pultruded CFRP spar cap planks while the blade stays on the turbine. Using finite element analysis on a 81.6-meter [00:01:00] blade from a seven-megawatt offshore turbine, the researchers found that a shear web window cut out as short as one meter drops buckling resistance from 20.7 times critical load to four times critical load, a reduction of over 80%.

The fix? Temporary external clamping frames with a pre-tensioned span-wise rod to carry gravity loads, combined with internal push rod assemblies and external stringers profiles to restore buckling resistance, all installed and removed uptower. Wow. I know we’ve discussed the carbon pultrusion repair situation and how critical that is or h- how difficult it is.

I didn’t realize it was that difficult, Rosemary, that if you actually try to replace a one-meter section of a carbon pultrusion, you’re re- reducing the, the, what, the, the buckling resistance by 80%? [00:02:00] Holy moly.

Rosemary Barnes: I don’t think that’s even 100% pultrusion specific, right? They’re talking about cutting a, a window in the shear web.

Allen Hall: Yes.

Rosemary Barnes: So that could be for any kind of repair you might have to do that, including if you need to repair, like sometimes you need to repair the, the shear web. Um, and even though, like, they’re not doing a lot of heavy lifting, um, that’s kind of a structural pun, um, they’re still super important. If they’re not there, then you’re gonna have big problems pretty immediately.

The way that it works with repairs is that there’s certain kinds of damage that you know that you can just do uptower. The technicians know they can do it. They don’t need to call an engineer. The engineer doesn’t call- need to call the expert engineer. But when you need to do something a bit unusual, like a whole meter of web removed, then you’re gonna need to get an engineer to, um, dial in the, y- the, to rerun the design codes basically, um, but with this weak structure now to see is this okay and is it okay, you know, uh, [00:03:00] obviously a turbine that is just, um, idle or it’s not even idle, it’s just fixed in place while they’re repairing it, that has different loads on it to one that’s operating.

So, you know, they’ll run that and make sure that it’s safe, um, before they do the repair. So what I really like about Fraunhofer is that they in some ways, like- Maybe it’s not cutting-edge science or engineering because they are largely repeating what is already well known in industry. But the problem is that industry doesn’t tell everybody else.

And so it is, like, such a vital role to then go and illustrate, um, to everybody else what, what’s happening in industry. And they, they are… Like, there is this problem with wind energy where academia and industry are not, um, talking too much, and a lot of the academic stuff just doesn’t relate at all to what’s happening in the industry.

But Fraunhofer do, like, 90, 90% of the time seem to get it at pretty right.

Allen Hall: When a carbon protrusion is [00:04:00] used, that really localizes where the load is versus in, in some of the more fiberglass designs that I’ve seen, the shell is actually taking some of the load. It’s not all in the shear web, so to speak. So doesn’t that sort of focus the loads into one location a little bit more when you move to carbon?

Isn’t that the point?

Rosemary Barnes: Yeah. Well, the carbon fiber is, is a lot, lot, lot stiffer than, um, fiberglass, and it’s, it’s a lot stronger. So yeah, you are designing… I, I mean, always the spar caps have been the main load carriers, the, um, you know, the main laminate, the bit between the shear webs or over the shear webs.

Um, but it’s, yeah, it probably is, um uh, e- exacerbated or the increased effect when you add carbon fiber. But the, the thing about carbon fiber is it’s so susceptible to small damages or small deviations, so like a tiny little bit of fiber waviness, like if your fibers aren’t perfectly straight, then you can easily get a, a crack.

And [00:05:00] carbon fiber can also be a lot less forgiving than fiberglass. It is not uncommon that it will just break, and you didn’t even know there was anything wrong. So that damage intolerance is what led to people moving away from carbon fiber fabric and into pultrusions, because they’re made with perfectly straight fibers.

Um, but it, it raises some, uh, problems of its own because y- yeah, like how do you repair that? You can’t, um, you can’t get the fibers as straight again unless you repair a whole plank, um, because like they look like, like two-by-fours or something. You know, like they look like little fence palings, basically.

Black, black fence palings. Um, and so yeah, you, you’d have to repair, replace a whole one, and then you’ve got like a big chunk of structure that’s missing there, so that’s pretty hard to do uptower. I, I don’t know anybody that does those uptower, actually. Um, m- maybe they can now with this reinforcement method, but I would still not enjoy being in a blade that was missing a, a [00:06:00] pultrusion and up in the air.

Allen Hall: The offshore versus onshore equation, it, it would make more sense onshore to actually drop the blade, I assume. Offshore adds difficulty, but it sounds like with all the rigging a- and assembly that you would have to do offshore, it, it probably is gonna be close in terms of total cost to do an uptower repair versus a downtower repair I would think.

It, it– Wouldn’t you think it’d be roughly right?

Rosemary Barnes: Yeah, like in, in offshore, there’s always more motivation to do complicated, um, expe-expensive uh, things that will save you from having to do something even more expensive, like bringing, um, a whole blade back. Uh, yeah, going out, getting the vessel with the crane, bringing the blade down, and taking it in is just incredibly expensive.

So you can spend a lot of time faffing around reinforcing a blade uptower before you, um, you know, would come out behind. But you know what? While we’re on topic of carbon pultrusions, I think it, like it, um, it’s almost bypassing the, the biggest risk with them ’cause [00:07:00] what I see is the– Like it’s one thing when you know you’ve got damage that you need to repair, but far more common, I think, is that you don’t even know that you’ve got damage.

It’s very hard to, to see what’s going on in there. Um, I mean, people aren’t just going up periodically and doing ultrasounds, ul-ultrasound scans of their entire blade. But even if they were, it’s still not that easy to find all of the, the little damages in, in pultrusions. So, um, yeah, that’s something…

‘Cause it’s not such an old technology. It’s been around for, I, I don’t know, like not even 10 years these have been, being used consistently, probably more like five, um, that there’s been a lot of them out there. And I just, yeah, I, uh, maybe I’m overreacting because all I see is broken blades in my career, but, um, you know, I am a little bit worried that we’re gonna start to see as, you know, fatigue builds up, that we might start to see some more like sudden breakages in these blades.

Allen Hall: If Fraunhofer’s working on it, there must be a reason for the [00:08:00] analysis and all the engineering time that they spent on it, that it’s a concern. I don’t know how you would do it offshore, honestly, because of all the wind loads. That you would have this damaged blade, and yes, you would have all the engineering calculations, but I would just see the safety people being very concerned about it.

Because if it does go free, you have a couple of people up there minimum, and who knows what’s below.

Rosemary Barnes: But even the amount of time in between knowing that you have to, um, replace a pultrusion and actually getting up there to do it, like I’d be surprised that it didn’t break in that, in that time because it is such a big, a big, a big thing.

Um, so yeah. Uh, but super interesting work and I do, I, I do really, really appreciate that the Fraunhofer exists to, you know, do this sort of stuff and, um, give us the information w-we need to get a better understanding.

Allen Hall: Delamination and bondline failures in blades are [00:09:00]difficult problems to detect early. These hidden issues can cost you millions in repairs and lost energy production. CIC NDT are specialists to detect these critical flaws before they become expensive burdens. Their nondestructive test technology penetrates deep into blade materials to find voids and cracks traditional inspections completely miss.

CIC NDT maps every critical defect, delivers actionable reports, and provides support to get your blades back in service. So visit CICNDT.com because catching blade problems early will save you millions

UK government has deployed 15 million pounds, uh, which is about $20 million, uh, through Innovate UK in a coordinated push to move offshore wind technology from prototype stage into commercial supply chains. The package has three components: a 10 million [00:10:00] pound offshore wind innovation program, open competition for high potential businesses, a five million pound wind innovation hub to align industry, government, and research, and a 12 million pound effort for phase one of a large structures innovation center on the Isle of Wight, with Vestas already signed as its first industry partner for sustainable blade development.

So the, the large structure innovation center is a composite center which is gonna be doing some advanced technology work on blade design. And I think there’s no better place to do that at the moment than in the UK. But it does open the door to a number of UK firms, and even outside the UK firms, to get involved in the UK offshore and somewhat on the onshore side.

This has massive potential, I think, within the UK and outside the UK, Matthew.

Matthew Stead: I, I know from my own firsthand experience that, um, uh, actually getting into the wind space is, like, really [00:11:00] hard. So for this sort of, um, incubator and support around, um, you know, setting up businesses, I, I think this is a really, really good thing for the UK government to be doing.

Um, ’cause, yeah, how do, how do you build up a future industry if you, if you don’t have the new businesses coming through? So I, I think it’s a, it’s a, it’s a great thing that the UK government’s doing. And yeah, and how do you get small companies working with the larger OEMs? How do you get the innovation?

Yeah, it’s, yeah, I think that’s probably, you know, got five gold stars for the UK government.

Allen Hall: What are the areas that they should be focused on over the next couple of years? Obviously, blades is, is a massive one. I’m sure Vestas is gonna be deeply involved with that. Are there some other areas in technologies that the UK should be orienting its supply chains towards?

Matthew Stead: I’m personally 100% biased towards blades ’cause w- we know that, you know, um, if we look at the failures and we look at the failure rate, you know, where is the greatest growth in failure rates? It’s blades. Um, [00:12:00]you know, why, why are we still having failures? Why haven’t we learned? You know, where is the knowledge exchange?

Um, so I- I’m biased, but I think it’s, it’s, it’s, it’s needed in, in the blade space. Yeah, as what, you know, Rosie and you were talking about before, um, you know, knowing more about, um, what’s going on, how it can be repaired, how it can be dealt with, I think is super, super critical.

Allen Hall: Well, Vineyard Wind has its 62 turbines in the water south of Martha’s Vineyard, but the project is delivering only partial power while GE Vernova works through its outstanding repairs.

Now, the financial pressure is breaking into public view on two fronts. Boston landlord BP Hancock LLC is suing Vineyard Offshore, uh, the Avangrid and BP joint venture, for nearly $1.2 million in back rent at its John Hancock Tower offices. Uh, separately, GE Vernova wants out of its turbine supply contract, claiming Vineyard Wind owes [00:13:00] it over $300 million.

Vineyard Wind fires back that it is actually owed more than 800 million from GE Vernova, so that, that saga will continue for a while. But it is a little odd that the rent is not being paid by Vineyard Wind at, at, in the John Hancock Tower. And if you’re familiar… That’s downtown Boston. If you’re familiar with downtown Boston, that, the John Hancock Tower is one of those iconic buildings you see in pretty much every downtown photo of Boston.

There must be a lot happening at the moment at Vineyard that they’re not able to pay the rent, or they’re trying to shuffle some money around or, or seek more financing. Sounds like they’re in a refinancing phase, honestly. Yeah,

Yolanda Padron: I know that at, at times there’s– it’s really common for, for an asset manager to think, you know, “Oh, we have X amount of money,” and then all of a sudden you– it’s all of the, the additional [00:14:00] repairs or the additional operational costs stack up to a bit more than they thought they were gonna have, and then maybe they don’t even have enough money to go do trash removal or anything.

And that happens, and it’s more often than, than we’d like to admit. Um, but this is on a bigger scale, right? Like, this is a project that we’ve talked a lot about, everyone’s talked a lot about, and it has a lot of eyes on it. And so for it to, to be so behind on rent on such an iconic place and such an important place and such an important part of the country, backed by a very important company, it’s really, it’s really interesting to, to think about kind of what they’re thinking.

‘Cause in, in my mind, right, like, if I was the people backing them, I would think, “Okay, well, the f- first thing’s first, like, let’s not give them any additional reason to hate us right now.” Right? Or like, you know, the public opinion is really big on these kind of things. Um, so I, I don’t, I don’t know what the, what [00:15:00] the exact plan is here.

Allen Hall: Well, I wonder if this is part of the, the negotiation with GE Vernova, that, uh, the, the payments and the, the power which leads to payments, uh, hasn’t been at it- its desired output from Vineyard Wind and is this an effort to, uh, shore up their legal case with GE Vernova to say, “Hey, look, uh, Avangrid’s not gonna throw a bunch of money in, even for rent.

This project needs to stand on its own two feet, and it can, but GE Vernova needs to be involved with it and get the turbines up and running to the level at which they were contracted to do”? Is this part of that play? ‘Cause it just feels like it. You know Avon Grid has the money to pay the rent. That’s not even a question.

It’s, but it’s why they are not doing it is probably the bigger question at the moment. Is, is it just all legal maneuvering at the minute?

Matthew Stead: I, I wonder if it’s a bit like, uh, you get the utility billing, you get the [00:16:00] electricity billing, you put it in the, the drawer over there, and then you forget about it, and then you forget to pay it, and-

Allen Hall: It’s a million dollars

Matthew Stead: $1 million out of, uh, 600 or whatever billions, you know? Maybe it was, maybe it was just a simple oversight.

Allen Hall: It could totally be oversight, but it’s, it seems like with the amount of attention that Vineyard Wind and GE Vernova are, are getting, and they are literally within a stone’s throw of one another, they can s- I’m– You could probably see the GE Vernova building from the John Hancock Tower, that, uh, you, you think that some of this would get settled, but it’s not.

It’s still going on. It’s, it’s crazy. It– With, and with Avon Grid and BP still being involved with it somewhat, uh, there’s something happening behind the scenes that has not poked its head up yet. It’s coming, though. This is all coming to a head pretty quickly. The– Massachusetts needs Vineyard Wind to run.

They really do, and it’s, it is a little surprising at [00:17:00] times that the state of Massachusetts is standing on the sidelines in this.

Matthew Stead: As wind energy professionals, staying informed is crucial, and let’s face it, difficult. That’s why the

Allen Hall: 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 peswind.com today. In this quarter’s PES Wind, there’s a lot of good articles in there. If you don’t have a copy, you can go to peswind.com and download one. A interesting article from Safe Lifting, which is a European-based lifting company that does basically bespoke engineering on lifts, and they’ve been making a push that’s saying that the next wave of projects depends on bigger [00:18:00] turbines, of course, which means bigger lifts, but they need to have some standardization to them.

Uh, things like spreader beams and rigging systems that are pre-built and pre-validated, uh, just reduce the overall engineering time it takes to do these lifts. Uh, and rental equipment models are a lot lower cost than buying OEM-specific or site-specific lift equipment, trying to keep the capital costs down.

That’s one of the big pushes in the wind industry is lowering the overall cost of installation. It does make sense, but it– as we were talking off-air a minute ago, a lot of lifts for basically the same kind of turbine are different. The, the connection points are different. There’s a lot of engineering that goes on there, and as the turbine sizes reach 15 megawatts plus, and the cells are massive, blades are massive.[00:19:00]

But it does seem like in a lot of other aspects of wind, there is some standardization, an IEC spec or some sort of overall guidance document for the industry that like, let’s put the lift points here, here, here, and here and lift with the right equipment. And Matthew, we just haven’t done it in lifting, even in smaller turbines, same thing.

Matthew Stead: Oh, it’s crazy. Um, I was, I was thinking about it, and, you know, my, my suggestion would be that, you know, when I buy 100 turbines, I should get, um, a blade lifting kit. It’s like when you buy a car, you, you get a, you get a kit to change the tire, don’t you? So I would’ve thought it would be just fundamental. Um, but, but, but we know that the wind industry is not always logical.

Um, so what is, what might be considered normal in a car is not normal for a wind turbine. Um, but yeah, uh, you know, this sounds like a perfect way of going to have more of a sort of standardized and, you know, not, not wait for the OEMs, but actually lead this and, and [00:20:00] drive this standardization. So yeah, thumbs up from me.

Yolanda Padron: I think this is really cool. Uh, I really hope that if we can standardize the way that we do that, we can make sure that the teams are trained in, like, the standard ways of, of lifting. I know that, um, I’ve, I’ve seen a few cases where someone didn’t know, there hadn’t- been exposed to a particular blade type and they were in char- you know, in charge of, of lifting it to, to, to do a blade replacement and then, um, they accidentally ended up damaging the blade and so you had this bad crack that they kind of painted over because it was a little bit embarrassing for them at the time.

And then, you know, a year later it’s like, well, okay, well, maybe next time ask someone, um, if you if you don’t know the, the exact lifting protocols or, or if you mess up, you know, let someone know. Um, but, but [00:21:00] yeah, the, you know, a lot of these, these smaller and, and larger structural cracks that, that come from, from lifting errors would be avoided if everybody was doing the same thing or the same two iterations of Of lifting standards, which is really exciting

Matthew Stead: Y- y- if you’ve got a wind farm, y- y- you’re guaranteed you’re gonna have to drop a blade at some point, aren’t you?

Allen Hall: And a gearbox

Matthew Stead: and a generator It’s, it’s pretty much a given. So like, like I said before, I reckon it should just be part of the standard kit that you buy, is you, you, you buy a substation, but you also buy a lifting, a lifting kit as well.

Allen Hall: It’s one of the more, uh, dangerous parts of wind is lifting, clearly, and we’ve seen that over time.

And, uh, having standardized equipment, back to Yolanda’s point, does make a lot of sense because if you’re out there doing this quite often and you have different rigging for every different OEM, you can get crosswise, and things happen. And if we had some standardization there, that would make a tremendous [00:22:00] amount of sense.

That’s why, uh, Safe Lifting wrote this article on PES Wind. So if, if you wanna read this article, just visit peswind.com. When engineers plan an offshore wind farm, they try to account for everything, including seabirds. And at the Horns Rev wind farm in the Danish North Sea, the layout was meant to leave birds a clear way through, but the birds had, uh, ideas of their own.

After 26 years of patient monitoring, researchers found that the turbines did not simply chase wildlife away. Instead, they reshuffled the entire neighborhood in the sky, turning some species into avoiders and others into opportunists. So this has been a big discussion in the wind industry for a long time, particularly for offshore wind projects, of what to do with the birds.

And the early assumption was that, hey, let’s just give them a pathway where they can fly [00:23:00] through, and birds have made up their minds. Some are taking that path. Others are avoiding it because of the change in the which, uh, species are hanging out where. This is a remarkable outcome, and it’s been going on long enough that there’s, uh, some statistical relevance to it now.

Do we need to get some bird psychologists involved in these offshore projects on how we think of how birds behave? Because I think to the engineering community, you know, like, you, you put a road there for you to fly through, bird, and then you decide not to. This is at a different level than engineering.

Yolanda Padron: I think it’s great to do as much as you can do, right? It’s amazing that they did all of this work. It is kind of funny. I mean, it’s, it’s sad. I’ve… I’m, I’m gonna get into trouble on LinkedIn or something by someone. I, I mean, it’s, it’s sad, of course, if, if birds get hit, right? But it’s, it’s, we can’t control everything.

You [00:24:00] know, as much planning that went into this, it’s

And what’s the next step here?

Matthew Stead: Well, first of all, 26 years? Is that correct? Yeah, 26 years. I mean, m- I, my- the thought that came to mind is that sometimes engineers don’t understand the natural environment. Sorry, just, just take that as a, as a observation. But, you know, I- it just reminds me of when, um, when civil engineers lay out paths and pavement, you know, they put a path in, but then people walk around it.

People do whatever they wanna do. And so, you know, I, I don’t think we can actually design out some of these things because we just will never understand the bird, we’ll never understand the human. Um, so yeah, I think put a little bit of effort in. I think going back to what Yolanda said, just put a, a bit of effort in.

But yeah, actually, there are some things in this world we can’t control.

Yolanda Padron: Yeah, I mean, [00:25:00] there’s, there’s of course endangered species. There’s of course, you know, a lot of, a lot of monitoring companies out there that do a really good job. Depending on what you need and depending on, you know… You can tailor your site needs around w- what’s gonna happen, right?

Or, you know, if you know that you’re in the migratory pattern of a particular species- There’s, I know there’s a lot of very smart people hard at work to make sure that your site is tailored to fit what needs to, what needs to happen there. And it’s great. I think it’s a great, it’s great to know, you know, that, that people in this industry care about birds.

I know I once had to go through extra check at TSA because the, the person there said, you know, “Oh, you work in wind? Save the birds.” And then he sent me through this, like, a lot, because he, he thought I was killing birds every day. Um, so I mean, you know, [00:26:00] we’re not killing birds out here, and it’s great, and it’s lovely to see all the hard work that goes into this.

But it, but it also, it’s, it’s important to note that the plans aren’t gonna be 100% foolproof, and that’s okay. You can just try your best.

Allen Hall: What’s the one bird you would assume as an engineer would not care if the wind turbines were there or not? The bird you see absolutely everywhere around the sea.

Matthew Stead: Seagull.

Allen Hall: Seagull. They do not care. They love wind turbines. They’ll use them as perches. I’m sure that, uh, yeah, a lot of, uh, technicians had to deal with seagulls, uh, hanging around the wind turbines. That has to be a thing. So it just depends on the species, for sure. Which is unique, right? E- every species has its own separate personality and things that it likes to do.

Uh, so in some of the wind turbines, I’m sure the seagulls are probably an annoyance, but they’re gonna let them be. And s- and some other species just don’t wanna be around the wind turbines, so even if you put a pathway through them, they’re just not gonna be [00:27:00] there. That’s an interesting finding.

Matthew Stead: It’s like onshore as well.

I mean, cows and sheep love to stand in the shade of a wind turbine, so they like to hang around. They scratch themselves on the, on the, the stair. You know, they, they rub themselves on the bolt covers. You know, they try and eat stuff. Goats, goats are particularly bad.

Allen Hall: Goats are really aggressive on wind farms for finding wires.

Absolutely. An- anything to eat.

Yolanda Padron: Raccoons.

Allen Hall: Yes. Raccoons.

Yolanda Padron: Snakes.

Allen Hall: The snakes do hide out in the shade. That is one thing you gotta be careful about is, uh, especially in Texas, of kicking over a rock and finding a snake, so make a lot of noise when you’re walking in Texas. That’s the plan. 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, and don’t forget to subscribe so you never miss an episode. And if you found some value in today’s conversation, [00:28:00] please leave us a review. It really helps other wind energy professionals discover the show.

So for Rosie, Yolanda, and Matthew, I’m Allen Hall, and I’ll see you here next week on the Uptime: Wind Energy podcast.

Vineyard Wind Battles GE Vernova, UK Funds Blade Innovation

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