Why Icing Costs More Than You Think

Ice build-up on wind turbine blades is often seen as a winter nuisance, but its impact extends far beyond energy production losses. Icing challenges the financial, operational, and reputational stability of wind farms, creating hidden costs that many operators may overlook. From accelerated component wear to safety hazards and downtime, the cumulative effects of icing can compromise profitability and turbine reliability.

Daniela Roeper, P.Eng.

Vice President BorealisWind

Addressing these risks requires proactive strategies like comprehensive ice protection systems, which safeguard assets while ensuring consistent energy production, safety, and compliance. Let’s examine the true costs of ice build-up on turbines and why effective mitigation is essential for long-term success.

 

1. Accelerated Turbine Wear and Damage

Ice build-up on turbine blades increases stress on critical components, such as bearings, gearboxes, and blades. This added weight creates imbalances that lead to excessive wear, reducing the lifespan of these parts and increasing the need for repairs. Drivetrain failures, often exacerbated by ice-induced stress, account for up to 13% of turbine downtime annually.

Maintenance becomes even more challenging in icy conditions. Repairing damage caused by ice often requires specialized equipment and skilled technicians, which leads to higher labor costs and extended downtime. Wind farm operators must also factor in the additional risks and expenses of accessing turbines during harsh winter weather.

2. Downtime and Revenue Losses

Icing causes turbine shutdowns or reduced performance during peak winter months, resulting in significant revenue losses. According to the National Renewable Energy Laboratory (NREL), ice can reduce annual energy production (AEP) by 3-10%, with extreme cases reaching as high as 20% in cold climates.

Restarting turbines after an icing event often takes longer than expected. Residual ice or system malfunctions can delay operations, compounding production losses. These missed opportunities during high-demand winter months can significantly affect financial performance.

3. Shortened Asset Lifespan

Recurring ice accumulation weakens turbine components over time, leading to structural degradation. Blades, in particular, are vulnerable to cracking, delamination, and other forms of damage caused by the additional weight and stress of ice.

This recurring stress also impacts the reliability of turbines. Frequent repairs not only increase maintenance costs but also reduce the dependability of turbines, making them less efficient over time. This shorter operational lifespan ultimately diminishes a wind farm’s return on investment.

4. Safety Hazards and Liability

Ice throw, where chunks of ice are flung from rotating turbine blades, is a significant safety hazard. Depending on wind speeds and blade size, ice can travel hundreds of meters, endangering technicians, nearby properties, and even public areas like roads or trails.

In addition to safety concerns, operators face potential liability for injuries or property damage caused by ice throw. Legal claims can result in financial losses, increased insurance premiums, and reputational damage. Proactively addressing ice risks is essential for minimizing these liabilities.

5. Regulatory Non-Compliance

Failure to mitigate icing risks can result in penalties or fines from regulatory bodies, particularly if safety incidents occur. In regions with strict safety regulations, operators may face significant penalties per incident, adding to the financial burden of icing-related issues.

Non-compliance with safety standards can also lead to heightened regulatory scrutiny, increasing administrative costs and operational challenges for wind farms.

6. Opportunity Costs of Missed Production

Downtime caused by icing prevents turbines from capitalizing on high energy demand and pricing during peak winter months. In some regions, energy prices during peak demand can be substantially higher than average rates, making missed production during these times especially costly.

Extended downtime also limits opportunities for reinvestment and growth. For wind farms looking to expand or upgrade their assets, these delays can hinder progress and reduce competitiveness in the market.

7. Reputational Damage

Icing-related incidents can undermine stakeholder confidence, particularly among investors, regulators, and local communities. Poorly managed icing risks may raise concerns about the reliability and safety of a wind farm.

This loss of trust can create a competitive disadvantage, making it harder to secure new projects or partnerships. In an industry where reputation matters, effective ice mitigation can be a key differentiator.

 

The hidden costs of ice build-up on turbine blades—from accelerated wear and lost revenue to safety risks and reputational damage—underscore the importance of proactive ice mitigation strategies. Comprehensive ice protection systems offer a reliable solution, safeguarding turbine components, maximizing energy production, and reducing operational risks.

Investing in these systems isn’t just about addressing immediate icing challenges—it’s about protecting your assets, ensuring consistent performance, and positioning your wind farm for long-term success.

Is your wind farm ready to overcome the challenges of winter? Take action today to ensure safety, profitability, and sustainability for the seasons to come.

 

Additional Information

How Comprehensive Ice Protection Works

Use Case: Wind Farm in Sweden Could Earn 67% ROI with Ice Protection

 

Sources

Wind Turbine Failures Review and Trends | Journal of Control, Automation and Electrical Systems

Icing losses – What can we learn from production and meteorological data.docx