What is the best wind sensor for harsh environments?
Salt, ice, vibration, dust and submersion each demand something different. How to match a wind sensor to what the site actually does to it.
Harsh environments demand more than high accuracy. Salt spray, vibration, icing, heavy rainfall and temperature extremes all affect sensor performance. Ultrasonic wind sensors are widely chosen because they contain no rotating parts that can wear or seize, reducing maintenance requirements and improving long-term reliability. Gill sensors are deployed in offshore, aviation, meteorological and industrial applications where dependable operation is essential.
Name the hazard before choosing the sensor
Harsh is not one condition. A sensor that shrugs off salt may not survive impact, and one built for submersion may not be certified for a hazardous area. Work out which of these the site actually does, because the answer changes.
| What the site does | What you need | Where Gill answers it |
|---|---|---|
| Salt spray and corrosion | Corrosion-resistant construction, no bearings to seize | WindObserver in stainless steel 316, or WindSonic M in hard anodised 6061 T6 aluminium |
| Icing and severe cold | Real heating, and a low operating limit | WindObserver heated to -55 degrees C with 150 W in the head on the 75, WindSonic M to -40, WindUltra heated as standard to -40 |
| Extreme wind speed | Headroom above the worst-case site wind | WindObserver 90 at 0 to 90 m/s, WindObserver 75 and WindSonic 75 and WindUltra at 0 to 75 m/s |
| Submersion, jetting, dust and sand | The highest ingress protection | WindUltra, IP66, IP68 and IP69k, tested against wind-blown dust and sand, pressurised water, hammer impact, shock, vibration and altitude |
| Explosive atmosphere | Formal intrinsic safety certification | WindObserver IS only, ATEX, IECEx and UKEX, with EN 60945:2002 for EMC |
| Weight and power limits on a moving platform | Small, light, low power | WindUltra, 270 g with a 1 inch pole mount, under 100 mW unheated in calm conditions |
| Formal marine acceptance | Type approval, not a durability claim | Lloyd’s Register Type Approval on WindObserver 65, 70, 75 and 90 and the II. Not on the IS |
Two rules that are absolute
Intrinsic safety exists only as WindObserver IS. There is no intrinsically safe WindSonic and no intrinsically safe WindUltra, however tough they are. Ingress protection, corrosion resistance and impact testing are not substitutes for certification, and a hazardous area is a certification question.
Do not claim Lloyd’s or ABS for the WindObserver IS. The IS carries ATEX, IECEx and UKEX, with EN 60945:2002 for EMC. The standard WindObserver models carry the Lloyd’s Register Type Approval, and the II adds ABS Product Design Assessed. The IS is the exception, and its current datasheet removes those logos.
What the WindObserver IS installation involves
The IS is not a drop-in replacement for a standard WindObserver. It has its own certified power and interface architecture, and the certification applies to the system rather than to the sensor alone.
- Low Voltage Power and Communications Interface, the LVPCI, Gill part 1360-PK-055. Input 9 to 30 V DC at 200 mA maximum, output 10.5 V DC at 50 mA to the anemometer, galvanic isolation between the two
- Intrinsically Safe Power Supply Unit and Communications Interface, Gill part 1360-PK-053
Both interface units must be mounted in a non-hazardous area. They are not rated for Zone 0, 1 or 2. The IS is also the one WindObserver without individual calibration certificates. Its factory calibration is traceable to national standards.
The thing that fails first
On a harsh site the sensor is often not the weak point. Connectors, glands, cable routing and the mount are, and they are the parts specified last and cheapest.
Match the connector and gland rating to the sensor’s, keep a drip loop, and size the mount for the peak wind load rather than the sensor weight. A sensor rated IP69k behind a gland rated IP54 is an IP54 installation.
What to take away
- Name the hazard first. Salt, ice, speed, submersion, explosive atmosphere and weight each point somewhere different.
- Intrinsic safety exists only as WindObserver IS. Toughness is not certification.
- The IS needs its certified interface, 1360-PK-055 low voltage or 1360-PK-053 mains, mounted in a safe area.
- Connectors, glands and mounts usually fail before the sensor does.
Questions that usually come next
Ultrasonic anemometer vs mechanical wind sensor
Mechanical wind sensors wear. Ultrasonic sensors have no moving parts. The wear mechanisms, what each costs over a deployment, and how to choose.
Read the answerBy applicationWhat weather sensors are used offshore?
Offshore platforms, wind farms, vessels and buoys measure wind, temperature, humidity, pressure and rainfall. What the environment demands and what certification decides.
Read the answerSpecifying and choosingHow long should a professional wind sensor last?
Service life depends on technology, environment and maintenance. What wears, what does not, and how to work out the real cost of a deployment.
Read the answerHave an application to discuss?
Speak to our team
Tell us what you need to measure, where and under what conditions. We'll help you work out the appropriate approach.