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Wind Turbine Cost: How Much? Are They Worth It in 2025?

by Dan Blewett

How much does a wind turbine cost in 2025? While renewable energy is no longer a “new” idea and large, green energy wind farms are more common – and more efficient – the combination of technology, construction, and operating expenses mean that a wind turbine’s initial cost is very expensive.

And calculating the “simple” cost of a wind turbine isn’t simple at all. Current projections for the cost of an offshore turbines cost is about $1.5M per Megawatt of power produced – meaning a 10MW wind turbine would come to about $15,000,000. But myriad factors go into the actual calculations.

For regular updates on wind turbine costs and the technology , people and policies driving the industry, follow the Uptime Wind Energy Podcast and subscribe to Uptime Tech News. It’s free! Subscribe now: https://substack.com/@uptimetechnews

Wind Turbine Cost: How Much? Are They Worth It in 2025?

Header image credit: GE Vernova

This article provides the numbers you need to understand how much does a wind turbine cost, do they actually pay for themselves over time, and is the upfront investment worth it?

As development for offshore wind farms has accelerated, over the past 20 years, the Biden Administration created some additional opportunities in the industry in the United States. As wind anticipated a second Trump administration, the economics of wind energy in the US were initially called into question. But both wind and the larger renewables market are bigger than shifting political policies. Since the renewable energy transition is well underway all over the world, the US is almost certain to remain a significant player. The mix of onshore and offshore wind energy is one of many unknowns that will affect the market, and specifically, the initial cost of a wind turbine.

When considering the cost of a wind turbine, it seems reasonable to pick one model of turbine to compare costs “apples to apples.” That alone is a daunting task, with cost estimates for off-shore wind more difficult to pin down than onshore wind, and costs of turbines designed for even modest-sized onshore wind farms vary based on the conditions of various wind farm locations.

Calculating even an “average” cost of a wind turbine in 2025 is a complicated math problem – actually, it involved numerous math problems and multiple conditions. We’ll explore several “solutions” to this problem.

In 2024, there were hints that manufacturers may reduce the number of models that they offer, for two basic reasons: profitability, and engineering reliability. If you’re not familiar with the wind energy market, it helps to start with a bit of an industry overview to understand how wind turbine costs are determined.

Are Wind Energy costs REally going down? Is Wind Energy Getting Too Cheap?

In recent years, wind turbine manufacturers like Siemens have expressed concerns that the cost of wind energy is getting too low to maintain the development and growth of the market. Rising costs, and government pricing structures present constant challenges to manufacturers.

In 2022, Nordex raised its turbine prices (approximately 12%) due to cost increases and rising interest rates; other turbine manufacturers increased prices as well. In 2023, wind turbine prices were more steady. Midway through the year, Nordex, based in Germany, recorded an average selling price of €890,000/MW or about $965,000/MW USD. [1]

In May 2023, Siemens’ Tim Dawidowsky famously commented, “it’s all about cash.” Obviously, Dawidowsky wanted to see European turbine makers get more money – and he’s not alone. When we reported on Dawidowsky’ s comment in an Uptime Podcast episode, we explained it in context with other concerns about energy pricing strategies. Nothing happens in a vacuum, and wind energy costs – including almost every piece of hardware in a wind turbine – are affected by myriad global factors more than most industrial products .

Of those factors, energy costs are the most difficult to pin down. Because different countries finance energy in vastly different ways, the industry absolutely does not enjoy a level playing field. While many European countries control energy developments outright – and other countries, like the US, has a long history of incentives and subsidy programs – it is difficult to determine actual costs, true profits and losses, and almost impossible to compare energy costs between nations. Even ‘simple’, hard costs – like blade and nacelle structures – fluctuate due to political policies and how they are expected to influence future prices.

The Biden administration’s IRA (Inflation Reduction Act) committed billions to green energy incentives from 2021-2024, and the effects of some of those programs continue. For weekly discussions on wind industry business and technology, listen to the Uptime Wind Energy Podcast here.

Where in the world are the most profitable wind projects?

IntelStor founder Philip Totaro addressed this question in the May 7, 2024 edition of Recharge News . Totato is a regular member of panel discussions on The Uptime Wind Energy Podcast.

How Much Does a Wind Turbine Cost Initially?

For commercial wind turbines, the answer is millions of dollars per turbine.

wind turbine cost

Wind turbines cost a lot, and as such the investment is to be recouped over a long period of time.

Turbines produce significant electricity and sell it back to local power utilities where it flows to the power grid, to be used by homes and businesses.

The Breakdown of Initial Wind Turbine Costs

  • $2.6 – $4 million per average-sized commercial wind turbine
    • Typical cost is $1.3 million per megawatt (MW) of electricity-producing capacity
    • Most commercial wind turbines have a capacity of 2-3 MW, but offshore turbines can be as large as 16-18 MW
    • Cost increases as turbine size increases, though there are benefits to using fewer, larger turbines – complexity and construction of the overall farm site is greatly reduced with fewer and larger turbines.

Interested in Wind Energy? Check out Our Wind Energy Podcast: Uptime

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Costs vary widely around the world. Why? It’s complicated

From Australia to Brazil to Canada to the UK, energy project are developed (read: funded and subsidized) in vastly different ways, largely due to different forms of governments. But there are many other stickier issues that make determining the cost of a wind turbine more difficult than your average accounting problem.

Different countries “adjust” the cost of materials, labor and land though artificially (or actually) reducing wages, and adding tariffs and taxes. In the US, well-intentioned initiatives like the Jones Act can increase the initial cost of wind turbine manufacturing – but in the long term, they should increase the value of the country’s wind energy market. The US isn’t the only country that creates such political constraints. Since 2022, throughout 2023, 2024 and well into 2025, the Jones Act is significantly impacting offshore wind turbine costs. In one August 2024 podcast episode, we detailed some of Orsted’s financial troubles. (Orsted is based in Denmark.) For more information on the business side of wind turbine costs and overall industry growth, listen to the Uptime Wind Energy Podcast every week. It’s eye-opening!

Wind Turbine Maintenance Costs

Once built, maintenance is an ongoing expense.

  • 1-2 cents per kilowatt-hour produced, or
  • $42,000 – $48,000 per year

Operation and maintenance costs can be significant, but all of these machines are long-term investments continue to (hopefully) pay for themselves over time.

wind turbine damage

A wind turbine study using German data showed that these costs can be 1-2 Eurocents per kilowatt hour (kWh) produced, on average.

wind turbine cost maintenance

This number climbs as the the turbine ages, which is not surprising considering the wear and tear and harsh environments these machines operate in.

How Operation & Maintenance Requirements Impact Wind Turbine Cost

Operation & maintenance (O&M) typically includes the following:

  • Insurance
  • Land costs, rent and taxes
  • Service, repair and spare parts
  • Administrative tasks
  • Power (it does take some electricity to run)
  • Miscellaneous

These recurring costs are not too significant, and the turbine will significantly outproduce the maintenance costs.

Repairs can be a significant capacity reducer (more on this later), and lightning strikes on wind turbines can be a real problem.

Though turbine blades leave the factor with a lightning protection system, often they are inadequate.

Especially for offshore wind turbines–where transporting workers for repair is costly and time-consuming–additional layers of lightning protection is important.

Products like segmented lightning diverters can provide additional protection from lightning strike damage to wind turbines.

How Much Electricity Does a Wind Turbine Produce?

We’ve covered costs, so now lets turn to the big question: how much electricity does a wind turbine generate?

wind farm up close

Wind turbines are sized in megawatts (MW), which refers to their capacity to create electricity.

One megawatt = 1,000,000 watts of power. One megawatt can power about 1000 homes for a month but in reality, wind turbines don’t come close to producing their rated capacity because of changing wind speeds.

Size of the Wind Turbine Affects Electricity-Producing Capacity

Wind turbines cost more the bigger they get, but they produce more electricity with larger nacelles and turbine blades.

offshore wind turbine

In its latest report on average rotor diameter size, Statistica said rotors for onshore wind turbines had risen to 129 meters (423 feet).

Common commercial wind turbine sizes in megawatts:

Offshore wind farms choose larger wind turbines in part because of the high cost of installing them and transporting the electricity, as well as the increased efficiency they gain with consistent, faster wind speeds.

It’s preferable to build one turbine rather than many smaller ones because fewer towers and ground anchoring systems have to be constructed, making everything less complicated.

Wind Speed & Direction Affects “Capacity Factor” in Electric Production

At full wind speed, a turbine can produce at it’s full capacity. If a turbine is rated for 2.5 MW, then at peak wind speed it will crank out 2.5 MW of power.

Yet, we all know that wind is never constant.

wind turbine capacity factor

Because the wind dies down, changes direction, etc., overall averages will be much lower, usually in the 30-40% range for onshore wind turbines and up to 65% (occasionally higher in rare circumstances) for offshore turbines.

Biggest Wind Turbine: GE Haliade-X 12-14.7 MW Turbine

The GE Haliade-X is…insane.

This enormous wind turbine was the first to offer 12 MW capacity, with blades 107m (351 feet) long and an overall footprint that reaches 260m (853 feet) into the sky. The Haliade-X offshore turbine features a range of power rating covering 12-14.7MW capacity. Want to buy one? It will run you $12M – $20Million. See how they’re installed:

<iframe width="1344" height="840" src="https://www.youtube.com/embed/XX2-DE0etcQ" title="Haliade-X offshore wind turbine - installation time lapse" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" referrerpolicy="strict-origin-when-cross-origin" allowfullscreen></iframe>

Turbines of this size are typically used offshore, where wind speeds are consistently much higher and delivering power is more complicated. Fewer, bigger turbines = easier power transport, fewer long-distance cables and a simpler overall system.

If you’re curious how these turbines stay upright in the crazy waves and wind out to sea, check out this article featuring some great illustrations.

How Much Money Does a Wind Turbine Produce From Electricity it Generates?

Remember that a wind turbine has a maximum rated capacity (such as 4 megawatts), but it will only produce electricity at a “capacity factor” or “load factor” that is a percentage of this maximum.

In the chart below, you’ll find some numbers based on the typical sale price (2019 data) of electrical power created by wind turbines. This power is sold back to the electrical grid of utility companies, and the price has been falling as turbine technology has improved.

This sale of electricity is how wind turbines pay for themselves and create renewable energy.

We want this power to be cheap, and it’s moving in the right direction.

Wind Turbine Cost: How Much? Are They Worth It in 2025?

The goal is for turbines to produce at a higher capacity factor, which means they’re creating more electricity for the time they’re in operation. A majority wind farms worldwide are heavily subsidized by government investment, however, wind farms in the US and elsewhere in North America operate in a more businesslike manner.

Many US wind farms not only pay private land owners for the use of their land, the energy producers also contribute mightily to the larger community through direct investment in addition to job creation and tax payments. To learn how some US wind farms contribute to their communities, see this brief overview of Wind Farms featured in the Uptime Wind Energy Podcast in 2024.

Need Lightning Protection For Your Wind Turbine?

Our StrikeTape wind turbine segmented lightning diverters are the most durable, highest-performing product in the world. Wind turbine maintenance costs skyrocket when constantly damaged by lightning strikes, so protect your turbines with the best.

Use StrikeTape lightning protection on your wind farm.

More Wind Turbine Questions & Answers

Check out our common wind turbine questions below, including many about wind turbine cost, specifications and more.

If you have a question, leave it below and we’ll update this article with our answer!

The towers on most commercial wind turbines are in the range of 200-260 feet tall. The blades, often well over 100 feet long, when counted in total height push the number well into the 300s. The Gamesa G87 model wind turbine’s blades reach a height of 399ft.

Wind turbine blade tip speeds regularly range from 120-180 miles per hour, though they vary due to wind conditions. Because of their enormous size (with blades well over 100ft), they look like they’re spinning slowly, when in reality blade tip speeds are very, very fast.

$1,300,000 USD per megawatt. The typical wind turbine is 2-3 MW in power, so most turbines cost in the $2-4 million dollar range. Operation and maintenance runs an additional $42,000-$48,000 per year according to research on wind turbine operational cost. See the National Renewable Energy Laboratory’s website for the most recent (December 2022) Cost of Wind Energy Review.

Yes, and these smaller turbines can now cost less than $1000. Energy production will vary greatly to the size, specs and wind conditions of a person’s home, and some homes may not be suited well for a turbine at all. There’s a reason that wind farms are carefully placed in very wind, often harsh conditions–high winds occur in places people often don’t want to live. If your home doesn’t get consistent, strong wind, it may not make financial sense to install any type of wind turbine. New turbine designs are constantly being proposed and tested.

Unfortunately, they sometimes do, but it’s not the largest threat to the bird population. Cats, and cell phone towers, are far more deadly to the bird population. This article sheds light on the issue: https://www.usatoday.com/story/money/business/2014/09/15/wind-turbines-kill-fewer-birds-than-cell-towers-cats/15683843/.

The number can vary greatly due to factors including size, wind conditions, blade length and of course, average home energy consumption. A typical wind turbine is generally capable of powering 1000-2000 homes in one year. One megawatt of energy production capacity will power about 1000 homes, and many onshore wind turbines have a 2-3 MW capacity.

The capacity factor–or load factor–is the actual power generation over time, rather than the theoretical maximum a turbine could produce. Because wind turbines can’t maintain peak production at all times (not even close) due to changing wind conditions, downtime for service, etc. – it’s important to consider capacity factor when calculating the expected power a turbine can produce over a year or more.

Most recent update May 30, 2024. Original article by Dan Blewett published December 20, 2021. Edited by Dan Blewett and Diane Stresing. The most recent and substantive changes since original publication date are noted below.

[1] (New citation, May 2024 update) https://www.windpowermonthly.com/article/1829900/nordex-sells-16gw-wind-turbines-pricing-holds-steady-q2#

  • The largest offshore wind turbines were updated to 18 MW
  • The National Renewable Energy Laboratory’s website was added to the frequently asked questions linking to the most recent (December 2022) Cost of Wind Energy Review.
  • Statistica’s latest figures on the Global Wind Power Market Statistics and Facts were reviewed in 2023 and 2024 when the latest figures available for most stats were based on a report completed 2021, available here. In January 2025, additional information was referenced from the Global Wind Energy Council’s report based on 2023 data.
  • References to recent podcasts and articles have been added.
  • This article may be updated periodically and substantive changes will be noted here.
  • This article was updated on January 5, 2025, to include some of the latest (2024) wind energy analyses and opinions from global data analytics and solution provider Wood Mackenzie
  • This article was previously on September 30, 2024 to include additional complications of breaking down wind turbine costs in various countries due to tariffs, subsidies, and other financial/political differences around the world.

https://weatherguardwind.com/how-much-does-wind-turbine-cost-worth-it/

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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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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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