GE Vernova Investigates Manufacturing Deviation in Vineyard Wind Blade Failure

GE Vernova has identified a possible "manufacturing deviation" as the cause of a recent blade failure at the Vineyard Wind project, which led to debris, including chunks of fiberglass, falling into the ocean and washing ashore around Nantucket. The U.S. Bureau of Safety and Environmental Enforcement (BSEE) has issued a suspension order to halt construction and operations at the wind farm.

GE Vernova's initial analysis indicates no engineering design flaw in the blade, nor any connection to a similar blade failure at the U.K.’s Dogger Bank Wind Farm, which uses the same Haliade-X turbines. The company attributed the Dogger Bank incident to an installation error.

During a Wednesday earnings call, GE Vernova CEO Scott Strazik announced plans to use non-destructive testing methods, such as ultrasound, to inspect the remaining 150 blades manufactured at the same Gaspé, Canada facility where the deviation occurred.

“Structurally, [turbines are] designed and certified to not do that, but you can’t guarantee that there won’t be a manufacturing defect in a blade,” said Theodore Paradise, a partner at K&L Gates who specializes in energy, infrastructure, and resources law. Paradise added that while the incident is not considered catastrophic, it has negatively impacted public perception of offshore wind energy.

Vineyard Wind’s communications director, Craig Gilvarg, stated that the company is aware of GE Vernova’s preliminary findings and continues its investigation. Vineyard Wind 1 remains focused on coordinating with BSEE, assisting in debris recovery, and prioritizing the safety of personnel, local communities, and the environment.

An Arcadis US report found no PFAS-containing materials used in the blade's manufacture, though it noted the presence of PTFE, a PFAS chemical, in small aerodynamic add-ons. The report emphasized that PTFE is stable, does not degrade easily, and is approved by the FDA for use in contact with food, potable water, and pharmaceuticals.

Arcadis US recommended continued debris recovery, inventory of recovered debris, and expanded assessment activities for potential human health and ecological risks associated with the debris.

In a recent filing with the U.S. Securities and Exchange Commission, GE Vernova indicated uncertainty regarding the timeline for lifting the BSEE suspension order. To date, 24 of the project’s 62 turbines have been installed, with completion anticipated later this year. The company acknowledged potential claims for damages and other costs due to the delay, which could significantly affect its financial position.

The incident has dealt a blow to the offshore wind industry, according to Paradise. "Those wins, those good developments and positive things, tend to get less discussion and less of a spotlight as opposed to something going wrong," he noted.

Vineyard Wind also faces a legal challenge in the U.S. Court of Appeals for the First Circuit regarding the Biden administration’s approval of the project, with oral arguments scheduled for Thursday.