Operations and Maintenance
NKE FERSA and Nanoprecise revolutionize wind turbine maintenance with their new cutting-edge Condition Monitoring System
This strategic partnership introduces an AI-based condition monitoring solution that promises to transform wind farm operations worldwide.
To redefine wind turbine maintenance, NKE FERSA, the Austrian-based premium bearing manufacturer, and Nanoprecise, the Canadian predictive maintenance specialist, are launching their new and innovative Condition Monitoring System for wind turbines.
“Our partnership with Nanoprecise represents a fusion of NKE FERSA’s deep understanding of wind applications and Nanoprecise’s innovative maintenance solution,” stated FERSA’s CEO, Rafael Paniagua. “This collaboration allows us to offer wind farm operators a comprehensive solution that not only detects potential issues before they impact energy production but also significantly extends the lifespan of the equipment,” added Paniagua.
An unprecedented technological breakthrough
The NKE Condition Monitoring System, equipped with Nanoprecise’s cutting-edge technology, combines a groundbreaking 6-in-1 wireless sensor with an advanced AI-driven cloud-based platform. This revolutionary system continuously monitors critical functioning parameters in wind turbines, such as vibration, temperature, humidity, acoustic emission, speed, and magnetic flux, providing broad and precise insights into the application’s performance.
AI-based predictive maintenance
At the heart of the system lies Nanoprecise’s patented energy-centric condition monitoring solution, which is composed of a gen-AI powered platform and an edge AI-equipped 6-in-1 sensor. Combined with NKE FERSA’s expertise, the solution delivers predictive maintenance information tailored to the needs of wind farm operators.
“Bearing faults are responsible for the majority of wind turbine’s planetary gearbox downtime. With our patented wavelet neural network enabled algorithms, we are able to diagnose faults on individual components in a gearbox,” stated Sunil Vedula, Founder and CEO of Nanoprecise.
“This means we aren’t just monitoring the health of the turbines, but providing actionable insights that can dramatically reduce downtime, increasing the availability of wind turbines, and making green energy more affordable,” he added.
Transforming wind farm operations
The NKE Condition Monitoring System promises to deliver rapid ROI for wind farm operators through:
• Comprehensive monitoring of wind turbine drivetrain applications
• Advanced predictive maintenance capabilities
• Quick and easy installation process
• Improved turbine performance and reduced downtime
• Extended equipment lifespan
Global impact and availability
Initially focusing on North American and European markets, NKE FERSA and Nanoprecise have plans for global expansion. The system will soon be available for wind farm operators worldwide, backed by comprehensive technical support that combines application knowledge, tribology, and vibration analysis expertise.
“This launch represents a significant step forward in wind turbine maintenance and efficiency,” added Hugo Santos, Chief Business Development Officer of FERSA. “We’re not just offering a product; we’re providing a solution that will contribute substantially to the growth and optimization of the renewal energy sector.”
Eawind, one of the first training providers to offer GWO blade repair training in Türkiye, has announced the successful completion of its periodic audit process.
According to the company’s statement, the training program, delivered under Global Wind Organisation (GWO) accreditation, aims to provide participants with a globally recognized qualification.
The company also expressed its appreciation to Dr. Duygu Hakan and the Bureau Veritas team for their professional approach and contributions throughout the audit process.
We4Ce, a Netherlands-based rotor blade engineering company, has signed a Memorandum of Understanding (MOU) with Thailand-based renewable energy developer CEWA Plus to scale on-site blade root bushing remanufacturing across Asia.
The agreement integrates We4Ce’s proprietary “Re-FIT” methodology and CNC Onsite’s mobile machining solutions with CEWA Plus’s on-site execution and quality control processes, forming a regional service network.
Serial orders are scheduled to begin in April 2026, with operations expanding across 12 countries including India, Sri Lanka, Thailand, and Vietnam.
A new approach to blade root maintenance
Blade root bushings are critical structural components connecting the blade root to the turbine hub. In certain blade constructions, material shrinkage or uneven distribution may lead to microcracks and reduced bonding strength over time.
The Re-FIT methodology enables precise removal and replacement of the damaged interface layer, restoring a factory-standard mechanical bond.
Compared to conventional repair methods involving blade transport or replacement, the on-site solution offers:
- Up to 60% cost reduction
- Lower CO₂ emissions
- Reduced downtime
New monitoring system: GapMaster Intelligence
The MOU also includes the integration of “GapMaster Intelligence,” a monitoring system developed by CEWA Plus.
Using high-precision laser scanning, the system continuously monitors the bond between the blade root and the bushing. Any detected gap triggers an automated alert via SCADA, enabling a shift toward proactive, condition-based maintenance.
Regional expansion and training
Technical teams from Asia will undergo training in Denmark and the Netherlands, covering machining operations, the Re-FIT process, and structural restoration procedures.
Following initial deployment in Thailand, the partners are also targeting expansion into Brazil and the United States, while developing solutions for offshore wind applications.
GE Vernova receives 1.1 GW of U.S. wind turbine repower orders, extending asset lifetimes, increasing output, and supporting domestic manufacturing.
GE Vernova’s Onshore Wind business has secured orders in 2025 to repower 1.1 gigawatts (GW) of onshore wind capacity in the United States. The projects are expected to reach commercial operation between 2026 and 2027.
The repowering initiatives will utilize nacelles and drivetrains manufactured at the company’s Pensacola, Florida facility, reinforcing domestic manufacturing activity and supply chain localization.
Extending Asset Life and Increasing Output
Repowering enables wind farm operators to upgrade existing assets by replacing key components such as nacelles and drivetrain systems, without developing entirely new sites. This approach increases annual energy production, improves reliability, and reduces long-term operations and maintenance costs.
As onshore wind fleets mature, repowering is emerging as a cost-effective strategy to extract additional value from established sites while avoiding permitting complexities and grid connection challenges.
A Growing Installed Base
GE Vernova’s Onshore Wind segment supports an installed base of approximately 59,000 turbines worldwide, representing nearly 120 GW of capacity. The company continues to expand its focus on lifecycle services and modernization solutions as part of its broader energy transition strategy.
Repowering as a Strategic Trend
Globally, repowering is becoming an increasingly important component of wind market development. By upgrading high-performing sites with modern equipment, operators can enhance output without expanding land use, while improving project economics and asset performance.
The 1.1 GW of repower orders secured in 2025 signals sustained demand for modernization solutions in the U.S. market and highlights the growing role of lifecycle optimization in mature wind fleets.
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