Leaning on technology to keep windmills running seamlessly

"Original equipment manufacturers (OEMs) have more important things to do, like developing and keeping pace with next-generation turbines, and operations often take a back seat. But, deploying the latest technologies into turbine operations is the core business for us," says Daniel Raj, co-founder and chief executive of GreenTech, a Coimbatore-based, tech-based wind asset operations and maintenance company. It handles operations, scheduled, predictive and corrective maintenance services, including inventory management and complex repairs.The company aims to tap the opportunity for independent service providers (ISPs) to operate, maintain older turbines and digitally optimise their performance, as the wind ecosystem in India matures and more assets come out of OEM's warranty period. They bet on outcompeting incumbents with data-driven tools, predictive maintenance and the resulting efficiency and cost gains. They also believe handling multi-branded fleets as key differentiation while competing in pricing. The startup was founded in 2018 by industry veterans and former head of Inox Wind, Saibaba Vutukuri, Captain Kishore Sundaresan, Daniel Raj, and P Mohan Raj.
Vutukuri, who is also an investor in the startup believes that as renewable assets mature, the industry focus is shifting from capacity addition to performance optimisation and life-extension. "This creates opportunities for ISPs who can combine engineering expertise with AI and ML-based asset management platforms, in India and global markets. GreenTech differentiates itself through engineering capability, engines and asset management platforms, providing higher availability and improvement in asset performance," he said. "Our AI/ ML-based anomaly detection and failure forecast engine predicts component failures in advance, allowing preventive replacement before breakdowns occur and avoiding cascading damage," says Daniel Raj. The company has developed in-house craneless lifting systems for major component replacements and a centralised control centre in Coimbatore monitors turbines to reduce downtime. He said their robotic blade inspection technology, which by imaging blades while turbines are operating under wind load, captures cracks that open under stress, enabling earlier detection. He believes only a handful of global players currently offer these capabilities. Daniel understood the need and prevalence of ISPs while working for Western clients after a decade-long stint in an equipment-making company. He believes more companies will adopt ISPs. It primarily caters to independent power producers (IPPs) and retail customers in industries such as steel, paper and textiles. He said competitive bidding has pushed IPPs to reduce the levelised cost of energy (LCOE), driving them to seek lower-cost O&M alternatives.GreenTech estimates the opportunity for independent providers is around 35GW of India's installed wind capacity after excluding older turbines and recent projects still under OEM warranty. Currently only 3-4GW is managed by ISPs. An additional 70GW projected to be added by 2030 is expected to significantly widen the aftermarket operations and maintenance opportunity as more assets transition out of OEM contracts.The startup has recently raised `30 crore in a round led by Transition VC. It is currently present across windy states and in Sri Lanka. With this infusion, it aims to expand its infrastructure and presence in southeast and west Asian markets. GreenTech will also deploy the funds to upgrade its predictive maintenance and analytics platforms and scaling inventory. It is expanding its repair facility, which includes electronic, electrical, mechanical, gearbox repairs and a 50,000sqft central warehouse at Paladam near Coimbatore. Raj says the company aims to grow at 100% annually over the next five years, betting that India's maturing wind fleet and global skill shortages in markets such as Europe will sustain demand for independent operators. The company is exploring the repowering segment, looking at ways to improve output from ageing wind turbines before they are fully replaced.