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Posts Tagged ‘GE Vernova’

LM/GE Vernova turbine blade plant. Photo credited by the New Bedford Light to Jean-Philippe Thibault/Journal Gaspésie Nouvelles.

On Oct. 24, Radio Gaspesie reported serious data falsification allegations related to the manufacturing GE Vernova turbine blades at their Gaspé, Quebec facility. GE Vernova’s delay in commenting on those charges is surprising given their economic and legal implications in both Canada and the US.

GE Vernova has informed the New Bedford Light that they have taken corrective actions at their blade facility in Gaspé after an extensive internal review of their blade manufacturing and quality assurance program. However, they have yet to comment on the data falsification allegations.

Actions speak louder than words, and the Light reports that GE Vernova laid off nine managers and suspended 11 unionized floor workers at the Gaspé factory. A representative for the union informed the Light that the production manager has been dismissed and the general manager has resigned.

Neither Vineyard Wind nor BSEE, the Federal safety regulator for the Vineyard Wind project, has commented on the matter. BSEE’s investigation of the blade failure is still pending and has seemingly gotten more complicated as a result of the manufacturing issues.

In addition to legal proceedings in Quebec, GE Vernova and Vineyard Wind are subject to possible civil and criminal penalties in the US. Civil penalties, which are administered by BSEE, seem likely given the extensive pollution from turbine blade fragments.

Criminal penalties, which are possible if the data falsification charges are proven true, are imposed by the Dept. of Justice. The applicable criminal penalties statute is pasted below.

43 U.S. Code § 1350 – Remedies and penalties – (c) Criminal penalties

Any person who knowingly and willfully (1) violates any provision of this subchapter, any term of a lease, license, or permit issued pursuant to this subchapter, or any regulation or order issued under the authority of this subchapter designed to protect health, safety, or the environment or conserve natural resources, (2) makes any false statement, representation, or certification in any application, record, report, or other document filed or required to be maintained under this subchapter, (3) falsifies, tampers with, or renders inaccurate any monitoring device or method of record required to be maintained under this subchapter, or (4) reveals any data or information required to be kept confidential by this subchapter shall, upon conviction, be punished by a fine of not more than $100,000, or by imprisonment for not more than ten years, or both. Each day that a violation under clause (1) of this subsection continues, or each day that any monitoring device or data recorder remains inoperative or inaccurate because of any activity described in clause (3) of this subsection, shall constitute a separate violation.

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See the translated excerpts below from a Radio Gaspesie report. This is a massive scandal if true.

“Yesterday, the vice-president of global operations at GE Vernova reportedly addressed all employees at the Gaspé plant to provide an update on the situation.

The investigation, led by GE Vernova’s lawyers, reportedly revealed that employees were asked by senior company executives to falsify quality control data. Data associated with a well-made blade was then associated with poorly made blades. Our sources indicate that this is a widespread practice in the industry.

The senior management of the Gaspé plant also allegedly implemented a points system that encouraged employees to skip verification steps, thus prioritizing production quantity over quality.

Our sources say the points system allegedly involved tight management oversight that bordered on intimidation of employees.

The oversized 107m blades that were produced in Gaspé for the construction of marine parks are said to be affected. The integrity of the entire production of the longest blades in America is currently being called into question.“

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Damaged Vineyard Wind turbine; Kit Noble photo
BSEE statement to the Nantucket Current

Comparing the above BSEE statement with recent GE Venova (GE) statements:

  • GE: We were “granted approval to return to installing new blades on turbines at the project once stringent safety and operational conditions are met.” (Positive spin of the BSEE statement implying that approval is assured.)
  • GE: “We have finalized root cause analysis and confirm the blade at issue at Vineyard Wind was caused by a manufacturing deviation from our factory in Canada.” (Then why doesn’t BSEE have the analysis? Is the Canadian plant being scapegoated?)

Finally, as expected, we can now conclude that the blades being shipped from New Bedford to France were defective.

Rolldock Sun arriving in Cherbourg with defective blades

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Breaking report from the Nantucket Current:

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The author of the New Bedford Light article about turbine blades being transported from New Bedford to Cherbourg posted (below) that there are six blades on the vessel.

It looks like she may get some help from French journalists who have picked up on this story. The Rolldock Sun is scheduled to arrive in Cherbourg on Oct. 16.

GE Vernova or Vineyard Wind could simplify things by explaining the shipment.

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New Bedford Light: The Rolldock Sun leaves New Bedford on Friday with two blades visible. Credit: Courtesy of West Island Weather

Per the New Bedford Light, the turbine blade delivery vessel Rolldock Sun was seen on Friday carrying at least two blades out of New Bedford. It was not headed for the Vineyard Wind site. According to vessel tracking websites, the Rolldock Sun was en route to the Port of Cherbourg, where GE Vernova has a blade manufacturing facility. 

The most likely explanation for returning the blades to Cherbourg is that defects were detected or suspected. The blade that failed, reportedly as a result of a manufacturing issue, is probably not the only one that was defective.

The New Bedford Light asked GE Vernova, Vineyard Wind, and the Federal regulator BSEE why the blades were being transported to Cherbourg. They received the following responses (my comments in parentheses):

GE Vernova: “No comment on this matter.” (This is the worst possible response. In the absence of information, people are left to speculate. If there was no problem with the blades, why wouldn’t GE simply provide an explanation? Their non-response simply reinforces suspicions that the blades were defective. If that is the case, why not take credit for procedures that identified the suspect defects, albeit belatedly?

Vineyard Wind: “The weekend has gotten in the way of the information flow,” and they would share information should they hear anything. Another request for information was not answered as of noon Monday. (Not exactly confidence inspiring from the company whose blade failure littered beaches and the offshore environment. They are deservedly being watched, and need to be more transparent and responsive.)

BSEE: A BSEE spokesperson did not answer questions and said by email that the agency has no new information. (Disappointing, but not surprising.)

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This real-life Spider-Man, seen on a Vineyard Wind turbine blade, is Tyler Paton. Tyler is an independent composite specialist who inspects and repairs blades on site. The Nantucket Current shared these images on X.

posted by Brian J @Mainsail23

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  • The “highly unusual and rare” talking point for turbine blade failures seems to have finally been discarded.
  • 3 new GE Haliade-X blades failed shortly after installation at Dogger Bank and Vineyard Wind. A total of only 48 turbines had been installed.
Offshore wind projectHaliade-X turbines installedblade failures
Dogger Bank272
Vineyard Wind211

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The operator of the wind farm released this short statement yesterday (8/22/2024):

We are aware of a blade failure which occurred this morning on an installed turbine at Dogger Bank A offshore wind farm, which is currently under construction. In line with safety procedures, the surrounding marine area has been restricted and relevant authorities notified. No one was injured or in the vicinity at the time the damage was sustained.

We are working closely with the turbine manufacturer, GE Vernova, which has initiated an investigation into the cause of the incident.

Further updates will be issued in due course as more information becomes available.

There have thus been at least 3 GE Vernova Haliade-X turbine failures at new offshore wind farms in 2024 – two at Dogger Bank and one at Vineyard Wind.

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In April 2024, a 72 meter, 22 ton blade from a turbine at the Odal onshore wind farm in Norway fell to the ground. 15 of the wind turbines at the facility were already out of operation, 13 due to blade defects. In 2023, Siemens Gamesa warned of quality problems at its onshore unit.
A Vestas turbine launched a a 7 ton blade and a shower of bolts amidst agricultural farmland at Portland General Electric’s Biglow Canyon wind farm.

As the above examples illustrate, turbine blade failures, like the Vineyard Wind incident near Nantucket, are not unique to GE Vernova. GE’s rivals, Siemens Gamesa and Vestas, have also experienced serious quality control issues.

Per ReviewEconomy (2023), “Unexpected and increasing wind turbine failure rates, largely in newer and bigger models, are savaging the profits of some of the world’s biggest manufacturers, as Siemens Gamesa, GE and Vestas report heavy repair and maintenance losses.”

All 3 manufacturers will be providing turbines for US Atlantic wind development. The table below lists the manufacturers for active projects with approved Records of Decision (RODs).

In light of the manufacturing challenges, all 3 companies report increased emphasis on quality control. Why has quality control to date been inadequate and how will the past problems be corrected?

Has the wind industry’s sense of entitlement, as evidenced in their tax credit, rate increase, and departure expectations, affected their safety and quality culture? Has industry and governmental wind energy promotion rushed development and compromised design and fabrication decisions? It’s time for wind developers, manufacturers, and regulators to make sure their priorities are in order.

projectturbine towersmanufacturer
Coastal VA Offshore Wind202Siemens Gamesa
Revolution Wind100Siemens Gamesa
Sunrise Wind94Siemens Gamesa
Atlantic Shores South200Vestas
Ocean Wind 198GE Vernova
Vineyard Wind 1100GE Vernova
Empire Wind 1 & 2147Vestas
New England Wind (phases 1&2)150Vestas

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