Industries
Wind Energy
Villari's technology enables continuous monitoring, minimizing the need for sporadic inspections and ensuring timely intervention.
Benefits of continuous monitoring
Extending the lifetime of wind turbine structures
Dealing with fatigue-prone bearings, blade roots, and tower welds that require frequent manual inspection? We collaborate with wind farm operators, engineering firms, and OEMs to continuously monitor the structural health of critical turbine components.
Our technology delivers precise insights into the remaining structural lifespan of steel structures through certified, permanently installed wireless sensors that detect small fatigue cracks in critical areas.
Continuous & accurate inspection
Early detection of crack detection ensures safety for the structure and its operators.
Competitive pricing
Wireless monitoring reduces the need for frequent manual inspections and prevents unplanned downtime and maintenance.
Carefree installation
Only 5 minutes installation time per sensor probe, no surface preparation required.
Reduced downtime
Confidently extend the lifetime of your turbine assets. Ensure that you maximise your generated energy.
Case study
Continuous crack monitoring on wind turbine pitch bearings
Pitch bearings are among the most fatigue-loaded components in a wind turbine. Cracks initiate at bolt holes and raceway zones in the cast steel outer ring - locations that are inaccessible during operation and costly to inspect without disassembly. Villari deployed wireless sensors directly on pitch bearing outer rings and blade root connections, monitoring continuously for crack growth without disassembly or production interruption.
Ferro One sensors installed at blade root - long flexible (500mm) and short rigid probe (75mm) and wireless transmitter.
Ferro One sensor probes (gold) installed along the raceway of the pitch bearing outer ring (render).
OPTIMISED MAINTENANCE THROUGH CONTINUOUS STRUCTURAL DATA
With continuous monitoring of pitch bearing and blade root structural health, operators can plan maintenance around production schedules rather than reacting to failures. The deployment provides certified, traceable data that supports lifetime extension assessments for fatigue-critical components.
This approach unlocks a proactive, data-driven asset management strategy - supporting longevity and reliability of turbine components across the fleet.
5 min
Installation time/probe
Up to 4.000
Measurements per year/sensor
48 hours
Maximum reaction time
API Integration
API integration with your CMMS/EAM system
30-60%
Reduction in inspection and maintenance costs
Onshore & offshore
Deployed across both environments
Wind energy presents two structurally distinct operating environments - and Villari's sensor system is certified and deployed in both. The challenge is the same in each case: fatigue cracks initiate at predictable locations, but accessing them for inspection is costly, weather dependent, and disruptive to generation.
Offshore turbines face the additional burden of marine access logistics, corrosive environments, and 50–80% higher O&M costs than their onshore counterparts. Permanently installed wireless sensors eliminate the need for inspection vessel mobilisation at critical structural locations.
OFFSHORE
Higher stakes, higher cost
Access requires vessel mobilisation, crew transfer, and precise weather windows. A single offshore inspection campaign can cost multiples of the equivalent onshore visit. Undetected structural issues carry the additional risk of extended downtime while waiting for a suitable access window.
Villari sensors at monopile welds, transition piece connections, and jacket nodes provide continuous data - eliminating the need for periodic access based inspection of those locations entirely. No surface preparation needed in these harsh environments.
Monitored locations
Monopile circumferential welds • Transition piece flanges • J-tube connections • Jacket nodes • Grouted connections
ONSHORE
Access is easier. Detection is not
Onshore turbines are more accessible, but fatigue cracks at tower door openings, flange welds, and pitch bearings still develop between inspection intervals. Manual inspection is time-consuming at scale across a large fleet, and inspection frequency is typically constrained by budget rather than structural need.
Villari's continuous monitoring ensures the structural condition of every sensor location is known at all times - replacing calendar-based inspection with condition-based maintenance across the whole fleet. With temperature ranges from -40°C to +80°C, the sensors can survive intense weather climates.
Monitored locations
Tower section welds • Door opening stress concentrations • Flange bolt zones • Pitch bearing outer rings • Nacelle bed plate
Ferro One sensors installed at an offshore wind turbine transition piece.
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Ferro One transmitter (green) and sensor probes installed on an onshore wind turbine tower - no surface preparation or drilling required
DNV certification confirms our commitment to improvement and sustainability. The DNV-RP-A203 qualification verifies our technology’s capabilities and limits, independently reviewed by DNV experts.
Other industries
Industries with heavily loaded steel structures
We work with asset owners, maintenance providers, NDT inspection companies, and engineering firms. We monitor bridges, cranes, girders and other critical steel assets across various industries. Reach out to explore new applications and lead the transformation in your industry.
