AI-driven digital twin for uncertainty-aware structural health monitoring of offshore wind turbines considering biofouling effects and reliability prediction
Marine biofouling on offshore wind turbine substructures poses major challenges to structural integrity and the dependability of vibration-based structural health monitoring (SHM) because it drastically changes mass distribution, decreases structural stiffness, and increases hydrodynamic loading. Conventional SHM methods often misdiagnose biofouling effects as structural damage. To address this limitation, the present study introduces an AI-driven digital twin framework that integrates artificial intelligence (AI), real-time Internet of Things (IoT)-enabled monitoring, and advanced numerical modeling to enhance damage detection and reliability assessment. The framework combines finite element analysis, computational fluid dynamics, and AI-based predictive analytics using convolutional neural networks, XGBoost, and Bayesian inference models to evaluate the dynamic behavior of four-legged jacket and tripod-type platforms under both clean and biofouled conditions. Real-time sensor data—including vibration, strain, and environmental measurements—are processed through machine learning models for accurate damage localization and predictive maintenance. Validation against real-world data indicates that biofouling, which increases structural mass by approximately 1,350 kg/m3, causes a 6–12% reduction in natural frequencies and distorts mode shapes, complicating conventional SHM interpretation. The proposed AI-enhanced modal strain energy approach, supported by Bayesian uncertainty quantification and frequency compensation techniques, improves damage detection accuracy by 15–25% and reduces false positives by 25%. Moreover, an IoT-based biofouling detection system further increases SHM reliability by 18%. A cost-benefit analysis reveals that AI-guided predictive maintenance strategies reduce inspection costs by 22%, decrease unplanned operational downtime by 60%, and accelerate damage detection by 30%. These findings demonstrate the potential of AI-integrated SHM systems to optimize offshore wind farm management, reduce operational risks, and extend structural service life.

- Black IM, Yeter B, Häckell MW, Kolios A. Assessing structural homogeneity and heterogeneity in offshore wind farms: A population-based structural health monitoring approach. Ocean Eng. 2024;311:118842. doi: 10.1016/j.oceaneng.2024.118842
- Xu JT, Luo L, Saw J, et al. Structural health monitoring of offshore wind turbines using distributed acoustic sensing (DAS). J Civil Struct Health Monit. 2025;15:445-463. doi: 10.1007/s13349-024-00883-w
- Sahu SK, Kumar V, Dutta SC, Sarkar R, Bhattacharya S, Debnath P. Structural safety of offshore wind turbines: Present state of knowledge and future challenges. Ocean Eng. 2024;309:118383. doi: 10.1016/j.oceaneng.2024.118383
- Yang Y, Liang F, Zhu Q, Zhang H. An overview on structural health monitoring and fault diagnosis of offshore wind turbine support structures. J Mar Sci Eng. 2024;12(3):377. doi: 10.3390/jmse12030377
- Melchers RE. Probabilistic model for marine corrosion of steel for structural reliability assessment. J Struct Eng. 2003;129(11):1484-1493. doi: 10.1061/(asce)0733-9445(2003)129:11(1484)
- Li Y, Wang S, Zhang M, Zheng C. An improved modal strain energy method for damage detection in offshore platform structures. J Mar Sci Appl. 2016;15(2):182-192. doi: 10.1007/s11804-016-1350-1
- Nguyen CU, Huynh TC, Kim JT. Vibration-based damage detection in wind turbine towers using artificial neural networks. Struct Monit Maint. 2018;5(4):507-519. doi: 10.12989/smm.2018.5.4.507
- Bouty C, Schafhirt S, Ziegler L, Muskulus M. Lifetime extension for large offshore wind farms: Is it enough to reassess fatigue for selected design positions? Energy Procedia. 2017;137:523-530. doi: 10.1016/j.egypro.2017.10.381
- Rolfes R, Zerbst S, Haake G, Reetz J, Lynch JP. Integral SHM-system for offshore wind turbines using smart wireless sensors. In: Proceedings of the 6th International Workshop on Structural Health Monitoring. Stanford, CA: Springer; 2007. p. 1-8.
- American Petroleum Institute. Recommended Practice for Planning, Designing, and Constructing Fixed Offshore Platforms-Working Stress Design. 21st ed. Washington, DC: American Petroleum Institute; 2005.
- Apolinario M, Coutinho R. Understanding the biofouling of offshore and deep-sea structures. In: Hellio C, Yebra D, editors. Advances in Marine Antifouling Coatings and Technologies. United Kingdom: Woodhead Publishing; 2009. p. 132-147. doi: 10.1533/9781845696313.1.132
- Bailey H, Brookes KL, Thompson PM. Assessing environmental impacts of offshore wind farms: Lessons learned and recommendations for the future. Aquat Biosystem. 2014;10(1):8. doi: 10.1186/2046-9063-10-8
- Devriendt C, Magalhães F, Guillaume P. Structural health monitoring of offshore wind turbines using automated operational modal analysis. Struct Health Monit. 2014;13(6):644-659. doi: 10.1177/1475921714556568
- Health and Safety Executive. Offshore Hydrocarbon Release Statistics and Analysis 1992-2015. Bootle, UK: Health and Safety Executive; 2016.
- Global Wind Energy Council. Record 6.1 GW of New Offshore Wind Capacity Installed Globally in 2019. GWEC; 2020.
- Chen IW, Wong BL, Lin YH, Chau SW, Huang HH. Design and analysis of jacket substructures for offshore wind turbines. Energies. 2016;9(4):264. doi: 10.3390/en9040264
- Martinez-Luengo M, Kolios A, Wang L. Structural health monitoring of offshore wind turbines: A review through the statistical pattern recognition paradigm. Renew Sustain Energy Rev. 2016;64:91-105. doi: 10.1016/j.rser.2016.05.085
- Samaei SR, Ghodsi Hassanabad M, Asadian Ghahfarrokhi M, Ketabdari MJ. Numerical and experimental investigation of damage in environmentally-sensitive civil structures using modal strain energy (case study: LPG wharf). Int J Environ Sci Technol. 2021;18:1939-1952. doi: 10.1007/s13762-021-03321-2
- Samaei SR, Riffat J. Intelligent structural health monitoring of jack-up platform legs using high-density sensor networks, real-time digital twins, and machine learning-based damage detection. Future Cities Environ. 2025;11. doi: 10.70917/fce-2025-031
- Tong Y, Liu W, Liu X, et al. Materials design and structural health monitoring of horizontal axis offshore wind turbines: A state-of-the-art review. Materials (Basel). 2025;18(2):329. doi: 10.3390/ma18020329
- Weijtjens W, Verbelen T, Capello E, Devriendt C. Vibration based structural health monitoring of the substructures of five offshore wind turbines. Procedia Eng. 2017;199: 2294-2299. doi: 10.1016/j.proeng.2017.09.187
