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Vineyard Wind Sues GE, Ørsted Overhauls Its Board

Vineyard Wind sues GE Renewables to block a walkout over $300M in withheld payments and defective blades. Plus Ørsted posts a $262M quarterly loss and shakes up its board.

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Matthew Stead: [00:00:00] 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, and I’m here with Matthew Stead and Rosemary Barnes who are in Australia. Before we get too far into this episode, I would like to mention that the UK US relationship has been very tense recently, as you have seen in the, in the news articles and on television.

But there was one good news piece that just happened, which is the band Oasis just got inducted into the Rock and Roll Hall of Fame. So that is trying to mend those relationships, bring the UK and US back together. In at least a musical sense. So I know Rosemary was watching that closely as the votes were counted.

But, [00:01:00] uh, everybody in the UK is super thrilled about it as they should be. And all us Oasis fans can’t wait for the induction ceremony. In fact, we’re planning to go to Cleveland. They’ll go watch it if we can. We shall see now onto more important information this week. Vineyard, wind and GE are not getting along.

And if you have been paying attention for the last two years, you would’ve noticed that there’s been a couple of tense moments. Well, uh, that wind project is a little bit up in the air because vineyard wind has filed suit against GE renewables to stop the turbine maker from walking away after GE sent a termination notice.

Over a $300 million ish, uh, disagreement in unpaid bills. At the center of this dispute are defective blades, of course, that, uh, broke off in 2024 and caused a number of problems, uh, for GE and vineyard Wind is particularly a delay in the [00:02:00] project and ge having to fix pull blades off of turbines that were already installed and I think they ended up sending those back to France.

Reading the lawsuit, it seems like GE did not repair those blades. They replaced those blades because, uh, they may not have been able to repair them or maybe is the amount of time it’s gonna take to repair them. You can repair almost anything made out of. Composite. Uh, but this is a big problem because, uh, if GE does walk away and they’re talking about walking away from this project at the end of April, vineyard, wind believes that the turbines are not ready to be operated, and they don’t have a way to operate those turbines.

They don’t have the knowledge or the people because the people belong to GE that need to make some of these turbines operate. Even there’s even some question about if all the turbines are operating at the required [00:03:00]handover requirements. This is unique because I don’t think I’ve ever seen a wind turbine manufacturer leave before a wind site is finished.

It must have happened before, but. It does put both sides in quite a pinch. Right.

Rosemary Barnes: Can I just jump, jump back to, to something that you said, um, that you can repair almost anything when it comes to composites? I would say that that doesn’t necessarily apply if your design was insufficient in the first place.

And I mean the design for manufacturing in this case, I think that the, like computer model design worked fine, but obviously it was not as easy to manufacture or as possible to manufacture. With the correct quality as what they expected. It can’t have been so simple to just, just repair. That’s, um, that’s what I want to say.

Like it, it’s obvious to me that if it was possible to repair, that would’ve been much easier than what they’ve ended up with, which I think is pretty foreseeable. Or most [00:04:00] engineers would probably have foreseen that if you, you know, put blades out there that, um, don’t meet your. Standard, um, quality control acceptance criteria that, you know, the consequence of that would be that it would be more likely to fail.

So yeah, I think you can repair nearly anything on a standard blade that is possible to make correctly. But if you’ve got big quality problems, then it’s not, it’s, it’s not easy and it’s possibly not possible to, you know, just get, um, just get onto that in repair.

Matthew Stead: I, I think you’re both right. Because it all comes down to economics.

So I think Alan’s statement, you know, things can be repaired. It just comes back to economics, doesn’t it?

Rosemary Barnes: U usually, yes. And like for your average, like if you’ve got a wind farm and you’ve got a blade with a big, a big repair, or you know, like a big defect right on the main laminate, that’s gonna require, you know, like a huge repair, taking the blade down and keeping it down for, you know, like three months while you rebuild like 20 meters [00:05:00] of laminate.

Yes, that would be technically possible, but you wouldn’t because it would be so expensive. So us usually, like in 99% of cases, that would be it. That it’s not actually impossible to repair. It’s just very hard. But, you know, in these really huge blades and, you know, um, bearing in mind that I don’t, I don’t know the specific quality problems that they face, but, you know, just from my knowledge of composites, you can say what the challenging areas would be, but you know, a really big blade is gonna have a really thick laminate and, um, composites don’t like to have really thick laminates.

When they cure, it’s usually an, an exothermic reaction, puts off heat, you know, like the temperature is changing and um, it works fine for thin laminates, but when it’s really thick you can get hot spots and cold spots and maybe it’s hard to get the resin to go all the way through evenly. But you know, imagine if you’ve got a really thick laminate and there’s a chunk of it that just didn’t get any resin in it.

How are you gonna repair that? Like, I wouldn’t say impossible. I’m sure if the fate of the human race depended on it, then you would, you would make it work. But it’s [00:06:00] certainly very close to impossible.

Matthew Stead: Economically, it does not make sense.

Rosemary Barnes: You would probably have to make a few inventions. Along the way to be able to make it work as well.

I think,

Allen Hall: I think I should read part of, and I don’t like reading these lawsuits, but this is informative in a sense that it provides some relative background as to what Vineyard Wind is thinking in some of the contract details that are involved here. So in June 4th, 2021, this is directly from the lawsuit, uh, vineyard Wind entered into A TSA with GE renewables in which.

GE Renewables agreed to design, manufacture supply, install commission, and test the wind turbine generators for the vineyard wind project at a contract price of more than $1.3 billion. There you go. On the same day as an integral part of the commercial agreement, the parties entered into an SMA, uh, by which GE renewables agreed to maintain and service that wind turbine [00:07:00]generators for the first five years.

Of operations of the project and guarantee that all wind turbine generators will operate at a 97% of production availability. Uh, this guarantee is central, is a central component of the commercial viability of the Vineyard Wind Project. So I would say so, right. Uh, at present, all of the wind turbine generators on the project have been installed.

However, the wind turbine generators are not yet fully operational and are. Able to reduce power at only levels well below those intended under the contracts fundamental to the project’s commitment to Massachusetts to achieve full commercial operation. The project requires repair, commissioning, and maintenance of GE renewables, 62 proprietary wind turbine generators, and their component parts work that only GE renewables knows how to perform.

So it sounds like Vineyard Wind has a five-year contract that GE ISS gonna operate these [00:08:00] turbines, and if they leave in a couple of weeks, vineyard wind really doesn’t have a backup plan. They may have. Were planning on a plan five years down the road where they could operate ’em, but to operate those turbines immediately when they haven’t, at least as.

Indicated here may not be fully commissioned to providing the right amount of availability. That’s a huge problem for Vineyard. Huge.

Rosemary Barnes: It’s interesting to me that they’ve decided to withhold some money that I think everyone agrees that they owe that money to ge. But then there’s a dispute because Vineyard when says that GE owes them money for some other stuff That sounds like GE disputes.

Um, it’s like if you have a problem. With your landlord, they always tell you, don’t, don’t withhold rent, because then they can, you know, that’s, that’s their out of the contract. Right? So it seems weird, like it’s a relatively small amount compared to what vineyard wind is risking. So. It seems to me like, are they, is this a mistake from them?

Are they giving ge an out from this contract that’s gonna be [00:09:00] really hard for them to meet? It might be that GE knows what it would cost to entirely fix the wind farm and have it producing the way that it should. But, you know, let’s say in a worst case scenario, that means remaking every single blade in the um, in the wind farm.

At the, at the French factory, you know, like that could be your, your worst case scenario. GE knows that that’s gonna cost more than what they’re ever gonna pay over the five years of, um, you know, the, uh, of missing the availability guarantee. So then it is worth, for them, the cost effective thing to do is to just walk away and they’re kind of, the amount that they’ll have to pay is limited.

If I’m thinking fairness, it’s so unfair that vineyard wind would be stuck with this wind farm that they can’t really get to do anything. But if I think about how I see these disputes work out in the smaller versions of them that I’ve seen, it seems like vineyard wind actually probably is the one more likely to come out with a bad outcome from the way that they’re [00:10:00] choosing to play this right.

Uh, because they, they risk not being able to operate at all. And they have potentially, like, I’m not a lawyer, I don’t, I don’t know about, you know, how likely it is that the 300 million, that their withholding will be enough for GE to walk away with without having to pay anything for, um, you know, not operating, uh, correctly over the next five years.

But, um, you know, it just seems like it’s not so much money compared to the billions that are at stake. To risk that they will be left unable to operate the wind farm at all. You know, it’s just, uh, I don’t know. It seems risky.

Allen Hall: Let’s start with the kickoff of what happened and what vineyard wind is alleging happened from these, their perspective on it.

It does provide some insight into all the things we talked about on the podcast for the last two years. We, we saw bits and pieces of it. According to vineyard wind, uh, GE Renewable [00:11:00] claims that it is owed quote amounts due unquote for milestone payments is, is contrary in in language to the TSA, so the turbine supply agreement put simply vineyard wind owes nothing to GE renewables because the TSA turbine supply agreement allows vineyard wind to withhold amounts.

The project engineer determines that GE Renewable owes vineyard wind from milestone payments otherwise due under the contract. So what they’re saying is GE owes is a bunch of money. Yes, we do owe GE renewables money, but it’s in Vineyard Wind’s favor. So why would they send GE money? Um, those set off amounts are substantial because GE renewables caused catastrophic injury to vineyard wind by installing 68 defective blades on 24.

Wind turbine generators resulting in two years of delay and over a billion dollars of damages. In July, 2024, one of the GE renewable offshore blades collapsed and fell into the waters off Nantucket resuscitating a massive environmental cleanup and requiring a six month [00:12:00] construction hiatus during which GE Renewable performed a root cause analysis, concluding that 68 of the 72 GE renewable.

Blades installed at the project, nearly all manufactured by GE Renewable in Gaspay Canada, and they say nearly all, not all, nearly all were also defected because they were inadequately bonded together, the original blades were so poorly made that they were beyond repair. Indeed, the federal government required GE renewable to remove all the blades and to replace all gas bay blades with others manufactured at a different facility in Sherbrook, France.

So that’s really the kickoff to all of this disagreement was the quality issues from Gas Bay. Uh, vineyard Wind goes on to say that GE Renewables and, and their CEO, Scott Straza, basically admitted to, uh, a, a serious, um. Overlook or quality issue? Quality escape, something of the [00:13:00] sort, uh, in some of the statements, which I, I remember him talking about

Rosemary Barnes: allegedly, in your opinion.

Allen Hall: Well, and Scott Streek did say it. In fact, here’s, here’s what Scott Streek did say. Streek, uh, acknowledged that the blade failure and said, quote, we have identified a material deviation or a manufacturing deviation. In one of our factories that through the inspection or quality assurance process we should have identified.

Because of that, we’re going to use our existing data and reinspect all of the blades that we have made for offshore wind and for context in this factory in Gus Bay, Canada, where the material deviation existed. That’s a quote. What happens now,

Rosemary Barnes: obviously I’ve never worked on anything that’s, this is the biggest example of, um, a, you know, a blade quality problem, a serial issue probably that’s ever happened in the wind industry.

I’ve never worked on something this big, but I have worked on probably half a dozen small, small versions that are quite similar. Um. To this, but just on a, you know, a much, much smaller scale. And I will say that it never [00:14:00] feels fair what the owner of the wind farm, like, what the outcome is, never feels fair to the owner of the wind farm.

Like when you’ve got a serial defect in, um, in play it like, and everyone suffers. It costs, it’s gonna cost the, um, you know, the manufacturer a lot of money. But I think that proportionally it is. Affects the owners more in nearly every case. It’s just there are some contractual things that you don’t end up with outcomes that feel, feel fair to anybody that, um, you know, would take a casual look at it.

So I don’t think that an outcome that feels fair is probably likely for, for vineyard wind. Um, and I guess it all just comes down to whether or not GE agree that they owe that 800 million or whatever the figure is. Um, or if a court finds that they owe it. Because surely the contract doesn’t say that Vineyard wins engineer at any time can just, or project manager can at any time decide [00:15:00] that, um, GE owes the money and so they don’t have to pay.

That obviously wouldn’t be a very, um, nice contract for GE to sign. So there’s gotta be some more nuance to it other than. That our project manager says, you owe us money so we’re not paying. And then, you know, you have to continue. Like, I, it’s probably impossible for us to, without, um, you know, having access to all of, all of the documents and the legal degree to understand it.

Probably, probably hard for us to Yeah. Come up with a, a reasonable conclusion.

Allen Hall: It does make you think, usually the progression is dispute. Whatever contractually is obligated in the beginning happens. And so if there’s someone who decides what pot of money goes where, that, that’s usually the first step.

Second step is usually arbitration in the us. I’d be surprised if they haven’t gone through at least an attempt at arbitration. And then once arbitration breaks down, then you go into the courts, which is clearly where they’re at now you’re, you’re at the highest level that you can be in terms of legal proceedings to try to sort this matter out.

And I’m sure both sides. Do not want to be in front of a [00:16:00] courtroom if they can avoid it. So there’s a much more to come about this. I, I think the other operators, uh, GEs this is, is this GEs only? Yeah. This is GEs only wind farm offshore in the us So this is it. But I would imagine that the other, uh, operators in offshore wind in the US or.

Being very careful word through contracts and how this is proceeding.

Rosemary Barnes: That’s something else I think about this case is that it’s going to be like the GE are the ones who have more at stake in terms of reputational harm. I would’ve thought then. Um, so. Yeah, that’s obviously a consideration that they’ve, they’ve gotta have, it isn’t, regardless of where the facts are, it’s not a good look.

Right. Um, to be seen, to be walking away from a wind farm. And it probably would make other people considering big expensive GE wind farms to be like, oh, you know, are we actually gonna get across the line with this? Or is there a risk that they just, you know, throw a tantrum towards the end and threaten to walk away and we have to renegotiate [00:17:00] everything.

So, um, I guess that there’s a, yeah, there’s always just the perception. Is as important in a lot of ways to what the actual facts are.

Matthew Stead: The thing I find is, um, I mean this is largely a legal thing, isn’t it? You know, we, we’ve agreed that it’s, with the lawyers, it’s a largely a legal thing. The, the sort of topic that I’m interested in is, um, like the example of you buy a car, you know, you buy a Toyota, um, you expect to be able to maintain it.

You expect to be able to run it and get a serviced by a Toyota, you don’t expect in the first year to take your Toyota to Ford and get them to fix it in the first year. The bigger issue is the turbine supplier agreement does not actually allow the turbine to be operated without the OEM, so no one knows.

No one knows how to run it. So for me, it’s a massive industry challenge, access of data, access of how to run a turbine. If the OEM is no longer there, so I think hopefully [00:18:00] this can have rama bigger ramifications for the industry that operators and owners can actually run the assets they own.

Rosemary Barnes: Well, there are companies that will come in and pull out your control system of your, you know, your turbine.

If it, you know, if you, um, if you don’t wanna work with them anymore or if the company went bankrupt, then there are companies that will rip it out and put a new one in. It’s not, not saying that that’s like an easy, cost effective thing to do and probably not gonna get the same, um, performance as, as you originally did.

But that’s what happens if you are, um, you know, your turbine manufacturer goes bankrupt and they just don’t exist to support anymore. Sometimes people have to resort to literally pulling out the whole control system and starting again. Not easy. When it’s something as big and new as this one obviously

Matthew Stead: isn’t the better answer that when you buy something, you actually buy the information to actually run it.

Rosemary Barnes: I don’t fully agree [00:19:00] though, because. It’s like, um, o often what you say, oh, you know, like this would be good. Like the one common thing is people say, oh, you know, like it’s planned obsolescence. People, engineers plan design things to fail so that you’ll need to replace them. And I think that that does, that does happen again in like consumer, consumer products.

Like, um, yeah, like your, your battery isn’t really designed to last for 10 years in your, your phone the same way that it is in an electric car. Um, more than 10 years in the case of an electric car. Um. But it’s not. It’s not what happens in industrial scale equipment. You are mostly worried about getting the price point right.

And if you want something to last longer, if you want something that anybody can come in and fix it easily, it costs more to engineer like that and usually like a a lot more. So it’s not just people like evil engineers or evil. Um. Evil management at these, at these companies.

Allen Hall: I already get to evil engineers.

Rosemary Barnes: No, people think it is. People think it’s evil. Engineers like purposely designing bad products to [00:20:00] um, make money, which I actually do think that they do with consumer products. Some of the time. Um, but when it comes to like industrial equipment, I, I don’t think that that’s the main, the main thing that planned obsolescence is not, is not a major factor here.

It’s about trying to get the price point competitive to make sales. And if you want to get better engineering, you, you will, you will pay for it.

Matthew Stead: I got a call with someone today that, which is on this topic. So, you know, we, we are a sensor company and, um, we pro we provide results, okay? So if we actually provided the raw data that we measure, it actually allows people, other people to reverse engineer our products.

So we don’t generally provide the raw data, so we provide the end outcome. Because it means that people can’t copy what we do. It means we can actually charge a lower price. So actually there’s a lot of logic to, you know, having, you know, [00:21:00] all these ways of engineering a product to, you know, give a better outcome to the end customer.

Allen Hall: I know Rosie doesn’t like Elon Musk, but this one of the things that Elon Musk did with Tesla at least, I don’t know about the other companies that he runs, but with Tesla, they went off and. Made patents, right? So they applied for a bunch of patents and received them and then just made them open use. And the reason they did that was so somebody couldn’t jump the patent line, create a patent about some car related electric thing, and prohibit Tesla from doing.

And so Tesla has always had the need to create patents that cost them, I’m sure, a, a pretty penny, just so they can avoid. Patent conflicts and lawsuits going forward. And it’s sort of the same thing, right? That the evil engineer bit, that’s the evil engineer bit I, that I don’t like is that when you get these crazy patent things happening out there that are just there to collect money and not do any of the work,

Rosemary Barnes: and some of the patents are.

Absolutely crazy. Like when you do a patent search and it’s like you’re [00:22:00] reading the language and like it sounds like they’ve just patented the concept of a wheel, you know? And then you’ve gotta try and figure out like what’s actually going on. Yeah. In

Matthew Stead: our world, someone has a patent around the Doppler shift.

Allen Hall: How can you have a patent on Doppler shift? That’s crazy.

Matthew Stead: It’s fundamental physical. You know, there’s a shift in frequency of a sound, um,

Allen Hall: based on speed

Matthew Stead: and yes, sound comes from a blade and there’s a doppler shift.

Allen Hall: That’s real. I, I, I guess, uh, see, that’s, that’s, that’s the craziness of that. See, you should have thought about.

The idiots that were gonna do that and then write a patent about Doppler shift.

Rosemary Barnes: It’s really annoying because it’s like, you know that it’s not gonna be, I mean, a lot of them you are like 99% sure it’s not gonna be possible for them to defend that if it gets challenged. But it’s like, to what extent do we trust that, you know?

Um, so you still usually end up steering around it anyway, but it, it really gets in the way of elegant engineering solutions. All these. Bizaro patents that are out there like clogging up [00:23:00] the design landscape.

Allen Hall: That happened recently. Right? Rosa? You had and I were talking about a particular patent. I thought had it existed and it did at one point exist and I.

Rosie said, I don’t, I don’t see it anymore. So I did some search on it. Yeah, it got pulled off. Uh, the list of valid patents. It was a lightning related thing.

Rosemary Barnes: And you were complaining that it was so obvious that they should never have been able to patent it, but yeah, and somebody obviously said, said something at some.

I don’t think patents are not the best way to protect an idea anyway. Right? Like nobody, if you, if you’ve got a new technology idea and you’re relying on a patent to protect other people from copying it, it’s not the best idea. I do work with a lot of small inventors who are like, oh, I’ve got a patent application, and they think it means something, that it doesn’t.

They think, oh, you know, patent was approved. That means it works. It means it’s a good idea. It doesn’t mean any of those things for like small, outside of big companies. I, I think it’s super rare that you would get more. You would get a positive return [00:24:00] on. On filing and maintaining a patent in all the countries that, um, are relevant

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 PES wind.com today. Sted posted a net loss of 1.7 billion Danish groner, roughly $262 million for the third quarter, as the cost of battling us anti win policies continues to mount the CEO. Rasmus abo, uh, says the company is about. One year into a turnaround plan, uh, that’s set to [00:25:00] run through beginning of 2028, and that the medicine is starting to work.

Uh, one major strategic change. Ted will enter partnerships on new projects far earlier, and so it will never again, uh, be forced into damaging late stage divestments The company maintained its full year EBITDA and, uh, guidance of, of, of. 24 to 27 billion Danish kroner. That’s a good bit of money. And the sale of a 50% stake in the horn, C3 to Apollo Global Management for a billion dollars is already under.

Well, at least in progress, but there’s a lot more behind the scenes here. Sted had an basically an investor meeting and a shareholder meeting, and, uh, they have three new board members. They let go of, if I remember correctly, three board members that were [00:26:00] employees that they just, uh, had reductions in forces that happen to affect board members, which is very odd.

Very, very odd in my. Humble opinion, having watched number of boards for a long time, usually don’t remove board members in that fashion, but there does seem to be a, a, a more emphasis on the board to help, uh, the CEO of stead get through some of these tumultuous times and maybe a little bit of concern about the, the, the way the board was constructed to get or sit back into profitability sooner rather than later.

This is a big deal up in Denmark. Of course, stead is the power company for Denmark. This has implications worldwide, though, uh, what stead does everybody else follows. And the one thing that, uh, that was sort of in dispute before the shareholder meeting was EOR at one point, was. At least contemplating a board seat.

And then right [00:27:00] before the meeting they backed off and said, no, it’s fine. We don’t want a board seat. Maybe they had some sense of what the changes were gonna be made to the board, so they felt better about it. But orsa is not out of the rough seas at the moment. There’s a couple more years of, of growing pains and learning some lessons that they wish they didn’t have to learn.

I guess that’s the way I would look at it. What implications does this have on the greater offshore wind community? Is stead taking basically a step back and, and trying to focus. Herding offshore wind, or is it just other, another companies are gonna step into that, that space that Sted may have previously occupied?

Matthew Stead: I think what you’re talking about, um, Alan, is, is all logical. I mean, you know, you can’t have everything. So, um, as in you can’t, you know, getting late to a project and expect it to go well, um, spreading risk is a good thing, you know, so the whole, you know, [00:28:00] doing it fast. Doing it cheap and doing it well. Um, you, you, you can’t have all of those things at once.

So actually what they’re talking about, I think is entirely logical. Um, so yeah, I think if they can lead the way that way and, and you know, I’ve come from, um, some other industries like construction and they, they spread the risk across multiple. Organizations that know what they’re doing. So the idea of joint ventures where you get the best of both worlds makes complete sense to me.

Allen Hall: Do they start making different decisions on projects based upon their financial stake at the moment? A And more importantly, when they start looking for offshore wind projects, are they likely to hook up with Vestas? Because I, I think that’s where this is all going.

Matthew Stead: Pick a horse.

Allen Hall: Yeah, they’re gonna pick a horse.

I, I mean, that’s the best, best way to think about it. They’re gonna pick a horse and gonna stick with them. Instead of having, uh, a lot of options and playing one against the other, I could see alignment happening, uh, versus being the [00:29:00] one offshore, of course. And or instead being a big player. There is, is that the combo that’s gonna push the industry forward?

Rosemary Barnes: Yeah, maybe. I mean, I think it’s more similar to what Chinese manufacturers are doing, a lot more vertical integration. You can, um, yeah, save, save a lot of money by doing that. It is. Uh, you know, not always ideal from other points of view. And it might be nice to have a, you know, a thriving technology ecosystem of, you know, different manufacturers competing with each other and, you know, making better products.

So, um, yeah, I don’t know, uh, have sit on the fence on this one for what’s good. I do feel really bad for osted though, like in terms of the, the. Shocks that they’ve had over the last couple of years. I, I don’t think most people would’ve foreseen that it would be so risky to try and expand into the US like everybody.

A few years ago, everybody thought that that was the next big profitable frontier in offshore wind. And [00:30:00] I don’t think that many people would’ve foreseen things going the way that they did.

Allen Hall: Is it the result of large industrial projects take time and that in that timeframe, five, 10 years, that the world changes so much?

You can’t. Accurately predict what the outcome will be and or it just got caught up in it.

Rosemary Barnes: Yeah, I think that’s actually one of the themes you guys have read, um, how big things get Done Right by Ben. Um, that’s one of the things that he mentions that the quicker that you can do the execution phase of your project, like spend plenty of time planning it, but when you’re actually committed, work super fast because the longer that you’re working, the more your chance of a, a black swan.

Um, a Black Swan event be, you know, a government that turns out to, you know, want to, you know, tear up contracts and you know, do all these other unprecedented stuff. You know, if you’ve got projects that take 10 or more years to build, then there’s just like a lot more risk of something like that happening.

And I think that, um, you know, like in some ways that’s just one of the inherent weaknesses of [00:31:00] wind energy in general, but offshore wind especially is that it does actually take a long time to get through all of the things that you need to do to. Um, to complete a project. And so it’s just, yeah, a lot more chance for, you know, the government will change two or three times probably in, um, you know, during a project.

How many wars can start, how many, you know, pandemics. Can there be you? Like, the longer that you’re going, you might think none of those things could be predicted and that can’t, but you can predict that those sorts of big things happen. And the longer that you, um, are exposed and the more of them that you’re probably gonna face.

And I think that, yeah, like something like a solar farm is much quicker to roll out. Um, battery projects are much quicker to roll out. So it’s just like that, those are benefits of those technologies compared to wind. You just have to kind of accept that that’s one of the weaknesses of this, this industry that we’re in.

Allen Hall: Is it a benefit to have solar because it can deploy very quickly, or, or is it just [00:32:00] smarter to have. More wind turbines of smaller megawatt outputs because you can manufacture ’em at scale quicker, and so the economies of scale don’t really matter so much. This is an argument we’ve been making for months now, that when you start selecting a single turbine, which doesn’t have any history, and it’s a big one, and it takes a long time to produce, you are really setting up yourself to fall into that window where something can go wrong.

Versus just stamping out two or three megawatt turbines and going like crazy. It just seems so much less risky.

Rosemary Barnes: I think that I definitely agree with you for onshore and then for offshore. Probably also, like I don’t think it’s necessarily go for a smaller turbine. It’s just don’t go for the brand new one.

Like that’s why I don’t understand how many people are like so obsessed with this, you know, small, small amount of improvement that they get from the very biggest. Turbine, but I don’t think that they realize the amount of technical risk. And I think that it gets, it’s getting [00:33:00] more and more like the, um, technology increment is getting more and more the bigger that we go.

It’s not that like, oh, we’re learning how to do this, this, well, it’s, it’s the opposite that, you know, like every, um, increment up in size as an exponentially more like larger number of problems, technical problems that have to be solved. And, um, I think that, yeah, that’s. That’s something people don’t factor in.

Allen Hall: Is it the gold rush problem where the miners were trying to hit that pocket of gold and spending all their time trying to find this gold, find this gold. In the meantime, a lot of them obviously broke, and the people that made money in the gold rush or the stores that sold the pickaxes, if you, you making a pickaxes, you have a customer page, you can just sell those things in.

Levi’s, be the other one, right? So they’re selling genes of pickaxes to the miners. Guess who won in that battle, right? Levi’s.

Rosemary Barnes: But what’s the analogy with win two of the pickax manufacturers,

Allen Hall: the people that make the two megawatt machines? In my opinion, that’s gonna be who the pickaxes are because you don’t have to think about it.

If [00:34:00] you can talk to operators of the United States today and you say, what turbine would you like to buy over again? And they will almost all tell you, GE one point fives. Almost all of them. And you go, yeah. Oh, okay. I understand it because it’s a machine. It’s pretty simple. But it does work. And it is, it is a true warhorse turbine.

And some of the vested ones are the same. Simpson Siemens turbines are very similar, right? Uh, but in today’s world, when we’re talking about 15, 20 megawatt turbines, I just think, man, you gotta be careful doing that just because of the time it takes to develop it and produce it, and. Work at all the kinks?

Uh, Rosemary, I think you’re right about that.

Rosemary Barnes: I think the issue is that, um, when you’re deciding whether to develop a project or not, it really depends a lot on what the spreadsheet tells you your return is going to be. And, um, you know, a bigger turbine with, uh, you know, like larger output over its lifetime, longer lifetime.

Those are all gonna give you really good. Spreadsheet numbers, but what’s not in the spreadsheet [00:35:00] is, oh, you know, you’ve actually increased your risk of having to wait two years while they replace every single blade in this, um, in this wind farm. Oh, by the way, yeah, you’re gonna be dealing with, um, you know, twice as many repairs and your, um, downtime is not gonna be 2%, it’s gonna be 3.5% or, or something.

You know, those, those sorts of things, I don’t think, uh, adequately captured in the, the spreadsheets whe say when you, whether you should or shouldn’t develop a new project.

Matthew Stead: So, so the evil engineering should be making decisions, not the evil lawyers.

Allen Hall: The financial people always make the decisions, right?

The insurance companies make the decisions.

Rosemary Barnes: Don’t think there’s a lot of engineering into, um, input in the, the very first stages. But I also think that if you put in the reality, like most engineers, I think are a little bit pessimistic because our job is to see what problems exist at, you know, and then solve them ideally.

Um, but at least part of it, like our brains are wired to look for problems, right? That’s, um, that’s a necessary part of the job, in my opinion. But if you were, you know, like pessimistic in your assumptions in the [00:36:00] spreadsheet, you would probably the majority of the time say, don’t make this project. The return is not very good.

Allen Hall: Well, that would be a smart move, right? Yeah.

Rosemary Barnes: Yeah. So I don’t actually think you probably should have too many engineers in in involved.

Matthew Stead: Yeah. But what is the CEO incentivized by is the, yeah, so it, it comes back to, you know, what, what, what drives the project And it’s not just engineering.

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 and 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. For Rosie and Matthew, I am Allen Hall and we’ll see you next week on the Uptime Wind Energy [00:37:00] Podcast.

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Pardalote Studies Australian Blade Erosion and Heat Fatigue

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Pardalote Studies Australian Blade Erosion and Heat Fatigue

Rosemary Barnes, CEO and founder of Pardalote Consulting, joins to discuss their new grant-funded study of blade erosion and heat fatigue in Australia.

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 YouTubeLinkedin and visit Weather Guard on the web. And subscribe to Rosemary’s “Engineering with Rosie” YouTube channel here. Have a question we can answer on the show? Email us!

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

Allen Hall 2025: Well, Rosemary, welcome back to the show.

Rosemary Barnes: Thanks, Allen. Great to be here. For, it’s been a while since we did one of these one-on-one episodes, like a, yeah, a proper, proper guest. 

Allen Hall 2025: Well, this is kind of a celebratory episode because your company, Pardalote Consulting, has been awarded, uh, some funding from the Australian Capital Territory’s government for the Energy Innovation Fund.

Rosemary Barnes: It’s a really good program that the ACT government has to try and get energy innovation In the state. It’s not a state actually, it’s technically a territory. Little more than just Canberra, the city. Uh, but there are actually quite a few, like, really interesting energy-related companies here, partly ’cause of the, the fund I think helps, but also just tracing back like, [00:01:00] uh, y- you know, in the 20-teens, Australia had a really conservative government that hated renewable energy, and the ACT government had a commitment at that time to 100%, um, 100% renewable electricity for the, the government.

And that was one of the only programs that was resulting in a lot of, um, you know, clean energy projects being built, and one of the conditions that they put on that, uh, for people that would win PPAs with the ACT was that you had to have your headquarters in Canberra. So we’ve actually got quite a few, quite a few really cool, innovative companies out of here.

Um, like Neoen’s headquarters here. Windlab, uh, yeah, was, was founded here and still has a lot of people here. Pardalote obviously, and you know, a few other companies as well. So despite it being a small city of like, I don’t know, maybe it’s up to 400,000 or something people by now, um, yeah, there is actually quite a lot going on here for energy.

Allen Hall 2025: And the Energy Innovation Fund is funded by the wind and solar operators in the area, and your particular [00:02:00] effort has really global consequences. You’re focusing on two areas involving how wind turbines survive Australia, but more, uh, of relevance is to just really tough conditions which exist not just in Australia but around the world.

What two areas are you going to focus on?

Rosemary Barnes: Yeah. So the two focus areas are leading edge erosion and high temperature fatigue, which we can probably get into the definitions of those in a minute. But basically my, um– what led me to wanna have a project like this was that when I moved back to Australia in 2021, I– and I started working in O&M, uh, I noticed that the wind turbines that I would look at, the blades that I would look at here behaved really differently to the ones that I worked with overseas.

You know, es- especially with leading edge erosion, like often I would be doing a condition assessment of a, you know, a new wind farm. Um, might only have been operating for, you know, two years. That’s a pretty common time for people to get in and do a condition assessment [00:03:00] because their warranty period is about to end and they wanna, you know, make sure that everything is okay.

Um, and I would just notice that often, like 90, 100% of blades would already have bad erosion after just a couple of years, which is super-duper fast. And then there are some tools available to check, um, like what kind of erosion are you likely to experience on your site. Like is it a higher severity erosion site or a, a low severity one?

Um, and you basically, you know, the status quo globally is to just look at the annual rainfall, um, and the tip speed. And if you’ve got, you know, high for both of those, that’s a bad erosion site. And if you’ve got low for both of those, it’s a, a low erosion site. But when I plotted out the wind farms that I knew had really bad erosion problems onto, you know, a chart with those two axes, I just saw a random distribution of dots.

You know? Like, this was not– uh, this had no predictive value for Australian wind farms. And so that led me to believe that, okay, um, you know, things are a bit [00:04:00] different here. Makes sense, you know, most of the knowledge that we have about how wind turbines operate, it’s been developed and validated mostly in Northern Europe.

You know? Like it’s, it’s Denmark and the surrounding countries that had, like, the bulk of the early wind energy. First few decades of knowledge were, you know, were mostly there. Of course, there were some other, um, places that had wind turbines, but, you know, most of the The OEMs have been operating for decades, came from Denmark.

And I know when I lived in Denmark, the rain there is very different to the rain in Australia. So in Denmark, it’s basically always raining, right? Like, it’s just… Like, even if it’s not raining, you’re still gonna get wet when you go outside ’cause it’s just, like, the air has this just amazing ability to just hold onto moisture.

Um, but it’s very, very gentle. But, you know, over an entire year of most days having gentle rain, that adds up to a lot. Whereas in Australia, and especially if you go, like, north to Queensland, it rarely rains. It’s mostly just dry, and when it [00:05:00] does rain, it’s like a tap turns on, and I, I swear you will get bruised from the rain droplets hitting your skin.

You know, they just have so much energy in them. So I think that that i- you know, when you look at just the overall rainfall, you really hide something important about how erosion, um, can progress. Then, um, there’s other places in Australia that have very different characteristics. Again, they don’t have that kind of really intense rain but, you know, some of those sites are also having really bad erosion.

And so it just occurred to me, I did a lot of research, you know, into what’s going on and, you know, the academics are studying erosion a whole lot, and they’ve got, you know, a lot of standardized tests and, you know, products are developed according to these standardized tests. But the standardized tests don’t actually resemble reality, and especially they don’t resemble reality in Australia.

And so my client started asking me, “Okay, you know, the products that we have are, are terrible. We have to replace them every couple of years. It’s, um, causing big problems with also [00:06:00] the amount of energy that you’re losing.” One of the types of, um, leading-edge erosion or leading-edge problems that we have in Australia is that the, the coatings tend to peel off and make these, like, big flakes which will just massively disrupt the airflow, can cause y- you know, at least a few percent AEP loss, and maybe up to five.

And even worse than the AEP loss is the revenue loss because it affects it most at, you know, lower wind speeds. Um, you get a bigger hit than at rated wind speeds. So there’s a variety of problems going on with leading edges in Australia, which mean that I, I basically… My clients would ask, “What product should we put on to prevent having to, you know, constantly replace this?”

‘Cause it costs, like- you know, 30, $40,000 per turbine to replace the protection, not to mention, you know, one or two days of downtime. It’s expensive, and I basically, I didn’t have a good answer for them. What, what product should they put on? I don’t know. No, we, we don’t know. One, we don’t know what the [00:07:00] specific, um, characteristics are that are…

what the specific local environment, local conditions are that are accelerating leading-edge erosion, one. And two, all of the products tend to be tested around this, you know, there’s this protocol that academics have come up with, and they’ve kind of like assumed that this is representative of how things behave in the field, and it’s– I don’t think it’s particularly true anyway, but it’s especially not true in Australia.

There are a few companies that are testing to different standards. Um, definitely applaud them. But without knowing wha- what are the conditions truly like in Australia, uh, it’s really hard to advise, like, what kind of tests should you be demanding from a product you’re considering to be sure that you’re gonna put it on and not gonna be replacing it again in two years.

Allen Hall 2025: Because that’s really the trouble in Australia is when you get offered products They have been tested generally in somewhere in Europe and maybe in the United States, and then when they go to [00:08:00] Australia, it’s really unknown as to how those products will do, which is a huge risk for the Australian wind market as to what to choose, how to choose, is it– what’s real in terms of test data.

So now you’re gonna go out and do what? Are you gonna put sensors out by the wind farms? Are you gonna try to do more of a statistical summary of the actual environment around wind farms using existing data? What’s the approach here?

Rosemary Barnes: It’s all of the above, but the part that is supported by the grant is that we’re gonna have enough money to be able to buy some scientific-grade sensors and put them on, um, a sample of Australian wind farms.

So we’re gonna be looking at a lot more characteristics about the rain than simply is it raining now, you know, how many millimeters per hour. We’re also gonna be investigating, you know, every kind of characteristic of, of that, um, of that rain, um, including, yeah, like the, the energy that’s in it, for example.

A, a bunch of stuff. I won’t get into every single [00:09:00] parameter. Um, and you know, other things as well, like measuring UV, solar radiation, um, particles, because, you know, in Australia we have a lot of dirt roads, which I know is very common in wind farms around the world, but Australian dirt roa- roads are always dry and dusty, like 99% of the time, so that’s one of the things that y- you know, maybe that’s causing a difference.

Um, so basically putting sensors all over a bunch of wind turbines and then monitoring the erosion, um, a combination of some real-time monitoring and also looking at inspection, um, drone inspection images annually. We also have a- an option where we’ll just be using SCADA data and inspection images, so that’s like a lower cost version where we can combine that with the findings from the scientific-grade instrumented turbines to build up a picture of what types of conditions lead to accelerated erosion.[00:10:00]

Allen Hall 2025: So the SCADA data will, will have some information inside of it, you think, that, uh, will correlate to the weather outside?

Rosemary Barnes: It has some Additionally, we can look up, um, you know, just the weather data, like how many millimeters fell during which 15-minute interval throughout the day, what was the temperature.

SCADA will tell us also what the temperature was, um, what the speed of the turbine was, so you can calculate the tip speed, ’cause that’s an important thing. Um, yeah, so it’s, it’s two, it’s two tiers of data collection. The scientific grade sensors, as you can imagine, are, are really expensive and y- you know, the, the grant project has contributed a, a lot of funding, um, but it’s not enough to put those, yeah, put a little mini lab on top of every turbine across Australia, obviously.

So that we’re using s- doing selectively, and then we can increase the number of wind farms that are included in the study by just doing this, um, cheaper version of the SCADA [00:11:00] plus, uh, weather data that’s available.

Allen Hall 2025: So what are some of the risks on the temperature side for all the high-temperature regions of Australia that have wind turbines?

Clearly it’s generally warmer in Australia than it is in, in Scandinavia and Northern Europe. What kind of temperatures are we talking about on the ground?

Rosemary Barnes: Uh, well, temperatures here can get pretty close to 50 degrees. Um, and if you’ve ever been inside a wind turbine blade on a, even a mildly hot day, you’ll know that the temperature inside a wind turbine, and especially inside the blade, is much hotter than what it is, uh, what the ambient temperature is.

So this project is one– I’ve actually been talking about this project for, yeah, like over 10 years now. Ever since I started, I moved to Denmark, started working for a wind turbine manufacturer, I had done– I had just finished doing my PhD on composite materials, structural design, and analysis. So, um, yeah, very, very familiar with, [00:12:00] you know, how composite materials work and, in particular, the effect that temperature has on them.

I mean, like most materials, when composites get warmer, they get softer, and that is really important for a w- a wind turbine blade. You know, if it gets, um, less stiff, then you’re gonna get a lot more strain, and that is going to affect your fatigue behavior. Y- you know, fatigue is just the application of a little bit of, a small amount of strain.

It’s not gonna cause damage, but when you apply it millions, tens of millions of times, like you do in a, o- over a wind turbine’s operate, um, operating lifetime, then that builds up. And, you know, wind turbine blades are a very fatigue-driven design. Um, it’s one of the most important things to consider when you’re designing a wind turbine blade.

And so when I got to Denmark and I learned how materials are qualified and how the qualification is treated in the certification process, I just realized it’s not particularly conservative, and also that some of the assumptions that are made that [00:13:00] wo- again, they worked really well in more moderate climates where wind turbines have had most of their developmental history.

You know, it’s not such a big deal there if you test at room temperature. Your wind turbine blade is spending most of its operating lifetime at room temperature or below. It’s, it’s rarely, you know, above 30 degrees in Denmark and most of Northern Europe and, you know, also a lot of, um, a lot of America, not, not all of it But, um, in Australia it has just extended periods above that temperature and even exceeding the temperature where, you know, wind turbines have an operating limit and after that they will shut down.

But the operating limits are based on ambient temperature. It’s not based on what’s the temperature in the laminate, which is what really matters for blade lifetime. So anyway, I’ve been obsessed, like honestly obsessed about this issue for 10 years. Talked about it with anybody who would listen . But then when I started working in O&M in [00:14:00] Australia and I started seeing some wind farms with an abnormal number of cracks early…

again, early in their lifetime, you know, I think one of the wind farms I was looking at was maybe three years old or four at the time. I think it was three actually, and had a lot of cracks, and I looked at a few years in a row and it was more and more cracks every year and I’m like, “Oof, this really looks like end of life fatigue behavior.”

A- actually it’s not, y- you know, there’s this concept of a bathtub curve where, um, when you’re looking at failures in components, in, in anything, not just in, um, wind turbine blades, but you know, like you’d start– it’s called a bathtub because, you know, when it starts operating, you’ll get quite a lot of failures.

Anything big, any manufacturing defects or anything are gonna cause failures quite fast, and that kind of drops off over time as all of those, uh, get addressed. And then you have, you know, the bulk of your operating life, it’s like pretty low level, pretty, pretty constant for a long time and then as you get towards the end of the [00:15:00] life, you start to see failure rates rise up again.

That’s your fatigue failures, your end of life fatigue failures. And so when I saw the same types of cracks more and more each year, I’m like, “This looks like, you know, the foot end of the bathtub, not the head end.” And, uh, it made me worried and I’ve now seen that across a few wind farms in Australia at, um, hotter places.

There’s a few blade types that are more prone to it than others, but at this point it’s still a suspicion that that’s what’s going on. I mean, a suspicion backed by a lot of, a lot of theory and knowledge of how the certification process works. But this project now we’ve got some funding to actually go put some sensors onto wind turbines, actually learn what the temperatures are in the blades throughout the whole laminate, um, not just the, you know, on the outside surface or not just the ambient temperature, but actually, you know, develop a temperature gradient across the whole, um, the whole laminate in the blade shell.

Um, and [00:16:00] then we’re going to be doing a bunch of modeling basically to look at what is the effect of these different temperatures that blades are really seeing and how much would we expect to… that to decrease a lifetime. And then we should also be able to say, you know, if you have this issue in your wind farm, you might be able to change your operation a little bit and extend your lifetime a lot.

Because this one, it’s real– like, in contrast to leading edge erosion, leading edge erosion is just, it’s, you know, every wind turbine has it to a certain extent, and it, it’s always there, but it’s a relatively minor cost to fix it. You know, like it sounds like a lot, like 30, $40,000 per wind turbine, but, um, you know, compared to if you’ve got to replace every blade across your fleet because they’re all, you know, at the end of their life after five years, you know, that’s obviously shocking.

And, you know, that’s a bad example, but even in a y- you know, like a less extreme example, maybe [00:17:00] after 15 years you have to do a, you know, a f- a fleet-wide campaign to strengthen blades or something. It’s, you know, m- many millions of dollars for that, and so it c- could make sense to be able to learn, okay, what, what hours of operation should we be avoiding?

Additionally, because when it’s super-duper hot in Australia, usually you’ve got heaps of solar power and the electricity price is not that high. So I, I think that there– and I don’t, obviously, before we’ve done the project, I don’t know what the threshold is. But in both cases, we will be aiming to improve the knowledge of how you can operate to avoid these periods of accelerated damage.

Allen Hall 2025: Do you think you’re seeing more fatigue-like damage due to the blades operating when it’s hot or not operating when it’s hot, with maybe less airflow around the blade and maybe less cooling going on is just a temperature soak At rest? [00:18:00]

Rosemary Barnes: Yeah. It’s interesting because the temperature is higher if it’s not rotating, um, because you get a whole lot of, um, convective heat, heat transfer when the turbine is operating.

So your temperatures are not gonna get as hot when operating as when they’re standing still. However, if it’s standing still, they’re only very lightly loaded. Like, yes, they’re gonna get, um, blown by, by gusts and, um, have a little bit of bending, but it’s, it’s very, very small compared to, uh, if it is y- you know, operational loads.

Uh, assuming that you’re not in the middle of a s- a storm. But yeah, a storm probably doesn’t come with 50 degrees temperatures.

Allen Hall 2025: And what part of the blade is susceptible to these higher temperatures? Is it the resin? Is it the fiberglass or carbon fiber? Or is it the, the glue, the bond joints? What part are you focused on?

Rosemary Barnes: The resin is the main part that I’m focused on. It gl- it could be an issue for glue too, actually. I haven’t even looked into what the, um, yeah, temperature assumptions are with, with glue, with [00:19:00] bond lines. But the failures that I’m seeing in the field are not, are not bond line issues. It’s, it’s, um, a laminate problem.

Allen Hall 2025: What about balsa and foam inside of the blade? Are they affected by the temperatures or are they pretty temperature stable?

Rosemary Barnes: I don’t think they’re affected at these kinds of temperatures, no. They, they don’t really do much actually. The, the core materials, like it, it is very important that they’re, that they’re there, but their job is really to keep the fiberglass separated from its- itself to make it stiffer.

So, um, yeah, that’s, that’s unlikely to be a, a major source of problems.

Allen Hall 2025: So this study is gonna work over about three years, and you have a number of wind farms that are participating. Are you looking for more wind farms to participate in Australia?

Rosemary Barnes: Yeah. Yeah, definitely. I mean, we can, um, have as many as, as people want to join.

We’ve got quite a good selection so far. Definitely can always welcome more. A, a bit limited in how many can get the really, um, good sensor [00:20:00]package, because the grant funding is a, you know, a certain amount, and that’s paying the bulk of those sensors. So, um, those spots are limited. So if anybody wants to really zone in on what is specifically causing erosion on their site, you know, if you know that you have got leading edge protection that is not good enough and you have to replace it soon, but you don’t know what to replace it with, then, you know, that would be the kind of wind farm that might want to consider, yeah, joining this and, um, you know, getting these sensors on their, um…

We’re putting them on top of the nacelles, most of them. Um, yeah, so that would be a good match then. Um, and then, yeah, for the ones that are doing the SCADA data and, um, weather data- There’s not such a, a hard limit on how many we can have join like that. So yeah, we can have more, more like that.

Allen Hall 2025: In the temperature fatigue effort, i- is that still looking for participants or are there particular wind turbine types or manufacturers that you’re [00:21:00] looking for to participate?

Rosemary Barnes: Yeah, I think, um, I, I mean yes, we can have more of those. That’s a simpler, a, a simpler issue as well. The sensors are not so expensive and, um, it’s, yeah, it’s a, it’s a simpler project to join that one. We only need, you know, a couple of turbines per site, so it won’t be such a, uh, an involved process to get everything up on into the turbines.

And in terms of who might like to join that, I would say anybody that is in a really hot area where, you know, where they see a lot of days over 30 degrees, and if they see any days, you know, getting into the high 40s, then I would say that that’s worthwhile. Or even I have seen this issue in some milder sites, um, yeah, depending on the, on the blade type as well.

It is more common with polyester resins. They have a, a lower op- uh, maximum operating temperature than epoxy resins. But then also just anybody that has noticed just, hey, [00:22:00] we’ve got a lot of cracks, and it seems like we’re getting more and more cracks every year, which to be honest, can be hard to keep track of if you’re…

If you’ve got a full service agreement, uh, you know, an OEM managing your wind farm The early signs of this are gonna be category one and category two cracks. They’re not in exactly the same location. It’s, you know, it’s a tricky one. Normally, if you’re looking at a serial issue, then you’re going to have, uh, well, you know, your ideal pattern for a serial issue is the exact same thing happening over and over again.

And so it is harder to pull this out. It also really would be very rare for it to be happening in the first two years or three years, whatever your serial defect liability period is. So it’s quite hard. But, um, another group of wind farms that might like to consider it is if you know that in, you know, a certain number of years you have to renegotiate your service agreement or, you know, it ends and you might have to take over yourself, then this’ll be a really good way for you to [00:23:00] understand, you know, have I got a ticking time bomb here?

Um, because it’s not something that you’re gonna be aware of if you haven’t been, you know, doing some really, really in-depth shadow, shadow monitoring of your blades, you know, running your own inspections and looking at every single damage, not just category three, four, five, but lower ones. So yeah, I mean, there’s a, a wide variety of people that, that could be interested in joining.

Allen Hall 2025: Are you expecting a number of manufacturers that make leading-edge protection or involved in resin creation, some– there’s a number of resin companies and a variety of resins that are used globally, sort of interchangeably at times. Are you expecting some of those companies to participate in this effort just to learn about the Australian environment?

Rosemary Barnes: I think it would be a good opportunity to test out some products and see how they behave in the Australian context. I think that that would be a really good selling point, but I, I have to say that most of the companies doing that sort of thing that wanna enter Australia, they don’t [00:24:00] really consider…

Like, from the perspective of wind farm owners in Australia, if you can’t show us wind farms in Australia where this has worked and, you know, show us a before or after, you know, the old LEP lasted Two years and our LEP is going on four years now with no damage. It, you know, unless you’ve got a before and after like that, you can tell us however many turbines that you’ve got installed around the world, but, um, we don’t consider it validated, y- you know?

It’s not validated for Australian conditions yet. And I do have this same discussion over and over again with, you know, not just leading edge protection, but all kinds of, um, you know, manufacturers of whatever doodads that you put on to improve a, a wind turbine. It’s so different to Australia. Things break so fast.

And I’m talking everything, you know, like vortex generators fall off and, um, yeah, like, uh, you know, bits of lightning protection systems fall off, seals just [00:25:00] crumble and disintegrate. Um, and it, you know, we’re very wary of, of new products. So I, I do– I mean, I’m thinking of it more from my client’s point of view than from the product manufacturer’s point of view.

But one thing that I wanna get out of this pro- project is to be able to answer one of the most common questions that I get is, which is, what leading edge protection should I be putting on my turbine? And for now, I don’t know. I, I know a range of products that don’t work in Australia, and not much more than that.

So, um, yeah. And it’s also, you know, Australia’s a very varied place with lots of different kinds of climate too. So it’s not gonna be like, you know, the product that works in Queensland is the same one that’s gonna work in Tasmania, which is the same one that’s gonna work in Western Australia. You know, um, so it, this project is gonna really pull out what are the site specific issues you’ve got at your site and what kinds of, um, you know, tests would we need to see a product um, perform in order to know that this [00:26:00] is gonna last on your site.

Allen Hall 2025: W- what is the outcome of this project or these two projects? Are they gonna be reports or, uh, a, a continual monitoring system that’s designed for the Australian environment? How do you see this going?

Rosemary Barnes: Yeah, so one part of it is, um, developing a way to identify periods of accelerated damage and to know not to operate during that time.

So we call it protective operation. Uh, so that would, uh, help you if, yeah, you’re trying to extend the life of something or increase the amount of time before you have to repair, then y- you know, that would be useful to have that knowledge. And it will be as simple as just an alert saying, “Hey, accelerated damage conditions.

Consider, you know, if you wanna keep on operating.” And, you know, if the price of electricity is super high at that time, they may want to push through, and if it’s low, they probably won’t want to. So that’s one thing. Um, especially, you know, as wind turbines get to their, near the end of their life. I’ve got some clients whose wind farms only have, you know, [00:27:00] maybe five years operation left.

They just simply don’t wanna repair their leading edge protection again. They just, they, they don’t wanna do that. So they would be happy to, you know, reduce operation a bit and have their turbine limp through to the end of the period. Y- you know, you want everything to wear out at once. You don’t want brand-new leading edge protection on a turbine that’s going to come down in a couple of years.

Um, so, you know, that’s, that’s one part of it. And then the other thing is, you know, turbines earlier in their lifetime, how can we optimize the maintenance schedule with leading edge erosion? Um, so, you know, like it’s a lot cheaper to, uh, replace the LEP if you get– catch it early, but then you don’t wanna be catching it too early and replacing it, you know, constantly when you, you don’t need to.

So, um, yeah, it, this, having this knowledge will enable a site-by-site operations and maintenance strategy with respect to leading edge protection. We also have some sites who are having trouble. They’ve got a full service agreement, and the OEM is [00:28:00] responsible for, um, doing the leading edge erosion repairs and protection replacement, but the owner is on the hook for paying for it.

At the other end, we’ve got people with full service agreements where technically the, um, manufacturer is supposed to be doing the leading edge protection and paying for it, but they argue about what, when does it need to be done. Because, you know, um, the operator might think if there’s no structural risk, then we don’t need to be replacing it.

And in the meantime, you’ve got turbines spinning around for years and years and years with, you know, these huge flakes of leading edge protection s- you know, causing the flow at the tip of the turbine to, to detach and to stall, and horrible aerodynamics, huge losses in power generation and revenue. And they’re having a big fight about, you know, is this necessary to do or not?

And then, you know, they’re just gonna put the exact same product on again ’cause the [00:29:00] OEMs are re- all really, really wedded to their own particular brand. It’s like, “Well, last time we had this product and it was factory applied, it lasted one year before it s- it was worse than, you know, if it wasn’t there at all.

Uh, we don’t really want you to put that one on again.” And so, you know, having the information that they need to be able to, you know, really bring data to these discussions and, you know, makes a, yeah, data not drama. That’s a, a good approach I think, um, for any kind of negotiation and especially in the case of leading edge erosion.

And then for the high temperature fatigue part of the problem, aside from, you know, just wanting to know are your blades aging, should you be looking at remediation action or changing the operation, the other really big key thing is, uh, you might need to have a fight with y- your OEM about if this turbine has been designed and operated correctly.

And so then having the data from this, um, project is going to give you the information that you need to come into that [00:30:00] argument with, again, the data not the drama. Um, and to, you know, in- increase your chances of succeeding in that kind of really tricky negotiation.

Allen Hall 2025: So if you’re an OEM or a manufacturer of equipment, an ISP, an operator, pretty much all aspects of wind operations, you probably ought to be getting a hold of Pardalote Consulting and Rosemary to talk about the opportunity to participate in this study.

How do people get ahold of you to, to do that?

Rosemary Barnes: People can go to our website, pardaloteconsulting.com, and get in touch via the contact form there, or you can, uh, look me up on LinkedIn, Rosemary Barnes. That’s probably the easiest, fastest way to get ahold of me personally.

Allen Hall 2025: Well, Rosemary, congratulations on the Energy Innovation Fund Awards and the new three-year effort.

If you are interested in participating with Pardalote Consulting and working with Rosemary and her team [00:31:00] in Australia, reach out to her on LinkedIn and get that process started, because this report and the data from all this analysis that’ll happen over the next couple of years will be important to the wind industry.

So you need to spend some time and get ahold of Rosemary and get this process started now. So Rosemary, congratulations. Uh, thanks for being back on the podcast, and looking forward to, uh, the next couple of years. It sh- should be exciting.

Rosemary Barnes: Thanks so much, Allen.

Pardalote Studies Australian Blade Erosion and Heat Fatigue

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Renewable Energy

Artificial Stupidity?

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We all understand that there are ultra-conservatives living all around us, but does anyone truly believe that our schoolteachers are ruining our society by teaching children the truth about U.S. and world history? Science? Current events?

Slavery and Jim Crow laws were bad.  Fascism is bad.  Our scientists are telling us that CO2 emissions are causing world temperatures to rise, destroying our planet’s capacity to support life.

Whom do these concepts upset?

Artificial Stupidity?

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No Such Thing as a “Dumb Question”

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There is nothing dumb about the question posed at left.  Democracies fail, falling into “banana republics” constantly.  The rate at which democracies become tyrannies is so great that some of them never make the news. Can you tell me anything about the governments of Eritrea or Chad?

What makes the situation in the United States is, yes, that it’s happening here in the United States, the very last place anyone would have suspected it.

You might have thought that Americans wouldn’t have voted for their nation to become Russia or North Korea.

You would have been wrong.

No Such Thing as a “Dumb Question”

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