Have you had an issue with the reliability of your turbine blade pitch control hydraulics? We might have a solution for you to increase the life and precision of the control system. 

Many of the top brands of wind turbines worldwide already trust the manufacturer Parker with filters, accumulators, and hydraulic valves. And now, some valves that are available for the US wind turbine market have been built in the USA. These proportional valves have been on the market for over 20 years in demanding industrial and mobile applications worldwide, with many upgrades and improvements over the years. Their use in the wind turbine market has been over ten years.

Hydraulically Controlling Wind Turbine Blade Pitch

Blade pitch control is a critical function of wind turbines for the overall control system. Wind turbines are designed to operate at steady rotational speed, usually about 15-20rpm for larger turbines. The gearbox increases the shaft speed to about 1,200–1,800 rpm to match the generator speed requirements to produce 60-cycle AC electricity at about 700V for the US market. The turbine controller starts the turbine when the wind reaches a given speed, usually about 10-16mph. A yaw drive keeps the turbine pointed into the wind to maximize electricity production efficiency. 

The pitch control system, located within the turbine hub, adjusts the variable pitch turbine blades to control the generator speed based on a feedback signal from the control system. On the hydraulically controlled blade pitch systems, there is one pitch control proportional valve per blade on a wind turbine. The pitch system also “zeros” the blades so that there is no lift generated by the rotating blades, thus shutting off the turbine drive when the wind speed reaches above 50 mph to protect the turbine from physical damage. An electric brake is usually engaged when the blades stop rotation.

The pitch control system operates in a very demanding environment, and the proportional control valve is arguably the device that is exposed to the harshest operating environment in terms of temperature and weather exposure. Failure of only one of the three valves will force the wind turbine out of service. Data from turbine farm operators confirm this observation with many field reports of OEM, sub-standard, pitch control valve failures within weeks of its first operation. An unexpectedly large number of failures occur within the warranty window of service. Upon failure, a maintenance technician must travel to the turbine site and replace the hydraulic pitch control valve in the turbine hub.

As you know, all the wind farms are remote and do not have on-site technicians, so this trip can be costly from a personnel standpoint, but it is even more costly for lost electricity production. Performing this service can take one or more days, depending on the site location distance and technician availability. The cause of the failure has often been traced to circuit board failure due to inadequate vibration protection or the circuit board enclosure design does not prevent dirt and moisture ingression. The cost of replacing pitch control valves is secondary to the cost of maintenance replacement evolution and the loss of energy generation.

A pitch control valve must be designed to operate full-time in an extremely rugged environment. First, most hydraulic pitch control valves are in the turbine hub, which rotates and is thus exposed to heavy vibration, shock, and rotational forces (up to 50G on three axes). The valves are also subject to lightning strikes, so the valve electronics must be electrically isolated from the turbine electrical system. Also, the pitch control valve must be capable of withstanding ambient temperatures ranging from -40C to 85C. It stands to reason that the pitch control valve should be designed to comply with IP65 standards for protection against dirt and moisture at a minimum.

Increase Your Reliability with a Parker Proportional Valve

One pitch control valve that has proven itself in multiple wind turbine applications is the Parker D1FC (nominal size: NG06, 5gpm flow rate) and the D3FC (nominal size NG10, 16gpm flow rate) direct operated proportional DC valve with onboard position feedback. The control valves receive an input signal, 4-20ma or +/-10VDC, from the main turbine controller based on its monitoring of the generator output. Internal valve flow and performance specifications have been matched to the system requirements of the turbine to be compatible with the existing controls so a replacement valve can co-exist with valves on the other axis. These hydraulic valves are designed to meet IP65 standard designation, which inhibits moisture and dust ingression. The D1FC and D3FC units are built to meet IEC 68- 2-6, -7, and -36 vibration standards so that random noise and shock loads, respectively, are well accounted for in the design and build process. The electronic driver card is installed with anti-shock mounting technology, which minimizes vibrational effects, and all fasteners are thread-locked to guard against vibration as an additional measure of safety.

Field service reports often state that mating connectors are the root cause of a turbine outage. The connectors used on OEM pitch control valves do not have locking connectors, so vibration can cause them to disengage. The D1FC and D3FC valve assemblies use locking mating connectors, similar to those found in the automotive and agricultural industries, which are vibration-resistant.

Major Design Features of the Parker D*FC Proportional Valve.

Parker is certainly recognized as a global provider of motion and control technologies, particularly hydraulic controls, which is why Ģ����Ƶ is proud to be a full-line distributor of its equipment. There is a further advantage for cost-conscience owners: a single replacement D1FC valve may be used in conjunction with two existing OEM valves, thereby allowing an incremental replacement program. This approach may be preferable for those owners who would rather replace them with upgraded components as repeated failures occur over time. Other owners may determine that changing all three valves may be the most cost-effective solution when the technician labor cost for multiple repairs and lost electricity generation costs are considered in the long-term costs of maintenance.

Parker offers a wide range of options for the D1FC and D3FC models, tailored to meet the demanding needs of wind turbines in the US market. For more information on this particular valve, see the on Parker’s website.

This table of products is a guide to what we have to offer, but please consult with us to determine if it is the right solution for your model and generation of Wind Turbine.

Ģ����Ƶ’s approach to solving the toughest proportional and servo valve issues on a variety of industrial and commercial machinery will go a long way to determining potential upgrades for your wind turbine blade pitch control.

Download the for more information. With thousands of parts at our disposal, the chances are high that we’ll have what you need, when you need it.

Contact me at steve.reynolds@rg-group.com to discuss your particular needs for extending the reliability, life, and maintenance intervals of your model and site.

What is a Bladder Accumulator?

Accumulators play an essential role in the operation and performance of wind turbines, storing hydraulic energy specifically for blade braking and pitch control functions. One of the many kinds of hydraulic accumulators out there are Bladder Accumulators. As its name suggests, bladder accumulators consist of a rubber bladder in the pressure vessel that separates the hydraulic fluid from the compressed gas. Bladder-style accumulators are a popular choice to use within wind turbines because of their universal application, durability, and cost-effectiveness, to name a few.

Like all accumulators on the market, bladder accumulators require regular maintenance to regulate the proper nitrogen pre-charge levels. This is because the material that is used has a large surface that is gas-permeable and can lose nitrogen through the bladder’s surface. While this is a simple repair, this is where those see an advantage of utilizing a piston accumulator. With the reduced surface area of the seals, the piston can hold the nitrogen pre-charge much longer than the bladder-style, not costing the time and money to spend recharging the nitrogen.

Whether you decide to utilize a bladder, piston, diaphragm, or other type of accumulator for your wind turbine, choosing a reputable supplier is vital to get the life, quality, and reliability out of your parts.

Where to Buy Quality Bladder Accumulators?

Sourcing high-quality accumulators from a reputable and trustworthy supplier should always be your top priority. Parker, a global leader in control and motion technologies, offers a range of hydraulic accumulator models that deliver precise regulation designed to regulate the performance of bespoke hydraulic systems. Parker’s Olaer division is known for making quality bladder accumulators for Wind Turbines. As the industry’s original, maintains the highest quality with their in-house bladder-molding operations suitable for various fluids and temperatures. Their newly developed global bladder models are engineered to meet all global requirements and certifications with in-house manufacturing to ensure they meet their highest quality and performance standards.

With its innovative and value-added design, the Parker is interchangeable with many of the OEM models while also having several advantages over them, including:

• Replaceable bladders
• Multiple compounds to meet lower temperature requirements
• AMSE versions for the US market

Along with Parker’s complete selection of bladder accumulators, they provide Bladder replacement Kits to repair existing accumulators without removing the shell from the system. Parker’s bladder replacement kits have a list of unique features specifically for the wind industry to ensure a long life, low nitrogen gas permeation, and a wide operating temperature range.

Here is a short list of some of the accumulators and repair kits you might find for your model Wind Turbine:

Accumulator & Wind Turbine Maintenance

A wind turbine is only as good as its parts and maintenance. If you operate or service a Wind Turbine facility, over time, there will be a need to replace or repair certain hydraulic systems with new, high-quality parts. Additionally, if your wind turbine utilizes bladder-style accumulators, it will need regular maintenance whether it’s refilling the nitrogen pre-charge levels, repair, or replacement. Servicing your accumulator and maintaining the proper nitrogen pre-charge is essential to the wind turbine’s performance, sourcing the right parts and working with the right distributor.

At Ģ����Ƶ, we service both OEM and maintenance providers – providing service, replacement components, and upgrades for wind turbine hydraulic systems. Whether it’s filters, valves, or accumulators, we can help you replace or offer better performance from your hydraulic parts. 

Improve Your Bladder Accumulators from Parker at Ģ����ƵĢ����Ƶ?

Ģ����Ƶ proudly supplies the industry’s finest products and solutions as a Parker partner and distributor. With Parker’s complete selection of bladder accumulators able to meet virtually every application on today’s wind turbines, we will match you with the right hydraulic solutions.

Ģ����Ƶ has been designing and building hydraulic projects since 1956. We are committed to excellence in engineering and quality control and will always deliver your products on time. We offer flexible outsourced manufacturing and provide you with in-depth and long-term support, assisting you through the design phase to engineering and production, field support, and more.

To discuss your needs in the Wind Turbine market or need to extend the life and maintenance intervals for your bladder accumulator model, contact Steven Reynolds at steve.reynolds@rg-group.com.

Learn more by visiting  Ģ����Ƶ’s hydraulics solutions, and downloading the Parker Wind Turbine .

Find Wind Turbine Parts from Parker at Ģ����Ƶ

Check us out at /solutions/hydraulics/ or download the Parker Wind Turbine product catalog at. With thousands of parts at our disposal, the chances are high we’ll have what you need, when you need it. If you want to discuss your needs in the Wind Turbine market, please contact me at steve.reynolds@rg-group.com.

Are your accumulators living up to their life expectancy or failing prematurely?

Diaphragm style accumulators are not repairable. This is why some wind turbine operators have switched to bladder accumulators. An option to diaphragm style accumulators are piston style accumulators. These come in both repairable and non-repairable versions with multiple compounds to meet lower temperature requirements. There are AMSE versions for the US market and CE for most of the rest of the world. Parker has been making quality accumulators for wind turbines for many years, but turbines come from all over the world in varying designs and quality. The OEM accumulators may not be giving you the life expectancy that is desired. The advantages of changing to a piston accumulator is a higher life expectancy and reduced risk of premature failure.

Where and how are you using accumlators?

The two main systems that use accumulators are blade braking and pitch control. Both applications use the accumulators to store hydraulic energy for use in case of loss of control pressure or hold a pressure without the need for additional power.

The issue with using a diaphragm accumulator is the failure mode, which is often catastrophic with no warning signs. The diaphragm usually tears. Once this device fails there is an immediate loss of control because the hydraulic pressure dissipates, and the system will no longer work. This could cause the wind turbine to run away and cause significant damage.

Do you need replacement or upgraded wind turbine parts?

If you have diaphragm or bladder style accumulators, you will need regular maintenance to maintain the nitrogen pre-charge. This is because the material used has a large surface that is gas permeable and can lose the nitrogen thru the diaphragm or bladder surface. This is where the advantage of the piston accumulator really shines. As the surface area of the seals is greatly reduced, sometimes as much as 15 times less, and therefore can hold a pre-charge much longer than the other styles of accumulator. As you can see in similar volume accumulators, diaphragm on the left and piston on the right, the seal surface is far smaller with the piston accumulators.

Although the piston accumulators cost more, the savings is usually worth the time the maintenance personnel have to spend recharging the nitrogen. If there is a full failure of the diaphragm, then for sure you would have wished you would have switched to a piston accumulator no matter what the fractional cost would have been for a better product with non-catastrophic failure modes.

I would also like to add that Parker put out a fantastic White Paper titled “Improve Wind Turbine Safety with a Piston Accumulator that delves further into why a change from a Diaphragm to a Piston style accumulator might be a good idea for both blade braking and pitch control. You can check that out here.

Whether you choose a repairable or a non-repairable piston accumulator, you will be improving safety and the life span of your wind turbine.

Contact me at steve.reynolds@rg-group.com. and we can discuss your particular needs to extend the life and the maintenance intervals for your model and site.

Why Choose Parker and Ģ����Ƶ?

More than 100,000 operational wind turbines have Parker products, demonstrating their expertise in this still-emerging energy resource. It is not unusual for plant owners and operators to inquire about the operating record of any new component proposed as a replacement. Potential suppliers expect those questions. A potential user should begin by investigating the track record of the supplier. Parker Hannifin has certainly been recognized as a global provider of motion and control technologies, particularly hydraulic controls, for over a century. Control of hydraulics has been at its core for almost as long.

Ģ����Ƶ has been around since 1957, distributing and incorporating Paker parts and technologies in their solutions since its inception. Our team of product specialists, engineers and fulfillment staff ensure that the Trusted Expertise the company is known for is delivered upon every day.

Find Wind Turbine Parts from Parker at Ģ����Ƶ

Check us out at /solutions/hydraulics/ or download the Parker Wind Turbine product catalog at. With thousands of parts at our disposal, the chances are high we’ll have what you need, when you need it. If you want to discuss your needs in the Wind Turbine market, please contact me at steve.reynolds@rg-group.com.

A wind turbine is only as good as its parts and maintenance. Without high-quality parts and regularly scheduled maintenance, you might face downtime that ranges from irritating to catastrophic. While working for major hydraulics supplier Ģ����Ƶ, I’ve seen firsthand the benefits of using quality parts sourced from a reputable supplier and the downfalls of trying to cut corners. (Hint: it’s never worth it!) Let’s discuss the difference the right partner can make in the uptime of your wind turbines.

Do you own or service a Wind Turbine hydraulics system?

Finding the right replacement parts is only half the challenge facing many industries today. Accessing them quickly is another. While improving, supply chain issues still seem to be a dilemma, plaguing businesses with lengthy downtime and repair and costs. If you’re operating a Wind Turbine facility, chances are at some point in time you’ll want to replace or retrofit some of your hydraulic systems with new, high quality parts. The right parts can make a world of difference when if comes to operating effectively and to the cost of ownership. So can working with the right product distributor make a difference. I work within a major hydraulic solution and distribution organization that services both OEM and maintenance providers that provide service, replacement components and upgrades for wind turbine hydraulic systems.

You might not have heard of Ģ����Ƶ, but I’ll bet you know of Parker Hannifin, the global conglomerate with thousands of products to meet the demands of hydraulic applications, including those in the Wind Turbine market.

Do you need replacement or upgraded wind turbine parts?

As a Parker distributor, it is likely that Ģ����Ƶ can help you replace worn-out parts or offer you better performance from your filters, valves, or accumulators. As in many other markets that we supply to, there is a significant difference in the life, quality, and reliability of our components. You can rest assured that Ģ����Ƶ and Parker have the expertise and quality products to make replacements worthwhile. For example:

Wind Turbine Filters: Using the right filter could save in the long term because the newer generation of filters are more efficient and have more dirt holding capacity. In addition, a more efficient filter could save on energy cost as the pressure drop would be lower if sized properly.

Wind Turbine Valves: We have the new generation of servo valve designed to be more rugged for the demanding blade pitch control. The new valves have higher response and are direct replacements for the North American Turbines.

Wind Turbine Accumulators: If you want longer life out of your accumulators you should consider changing out the bladder accumulators for a piston accumulator design. You will not only have less maintenance, but when maintenance is required the seal kits are less expensive and easier to change out. 

Why Choose Parker and Ģ����Ƶ?

More than 100,000 operational wind turbines have Parker products, demonstrating their expertise in this still-emerging energy resource. It is not unusual for plant owners and operators to inquire about the operating record of any new component proposed as a replacement. Potential suppliers expect those questions. A potential user should begin by investigating the track record of the supplier. Parker Hannifin has certainly been recognized as a global provider of motion and control technologies, particularly hydraulic controls, for over a century. Control of hydraulics has been at its core for almost as long.

Ģ����Ƶ has been around since 1957, distributing and incorporating Paker parts and technologies in their solutions since its inception. Our team of product specialists, engineers and fulfillment staff ensure that the Trusted Expertise the company is known for is delivered upon every day.

What if you are under no obligation to your OEM for warranty replacement parts?

If you are no longer under obligation to the OEM for warranty replacement parts, look to Ģ����Ƶ and Parker Hannifin to see how we can help you improve efficiency, safety, or uptime with our Wind Turbine solutions and products.

Find Wind Turbine Parts from Parker at Ģ����Ƶ

Check us out at /solutions/hydraulics/ or download the Parker Wind Turbine product catalog at. With thousands of parts at our disposal, the chances are high we’ll have what you need, when you need it. If you want to discuss your needs in the Wind Turbine market, please contact me at steve.reynolds@rg-group.com.