WIND TURBINE

HYDRAULIC
SYSTEM:
OPERATION AND
MAINTENANCE

Outline

Introduction to turbine hydraulic system

Description/Location of hydraulic system
Wind turbine hydraulic oil
Wind turbine hydraulic filters and filtration elements
Flow and pressure control valves
Pumps/motors, cylinders, and accumulators
Wind Turbine Hydraulic System
Blade pitch control
Distributor and Membrane blocks

Rotating joint
Rotor brake
Yaw system brake clamps
Hydraulic system schematics
Hydraulic system maintenance
General considerations
Common maintenance issues/Troubleshooting/Solutions

What is Hydraulics?

The pressure in a static

hydraulic fluid in a closed
system is the same
everywhere.
If the ratio of the areas is 5, a force
of 100 N on small piston will
produce 500 N of force on large
piston.
However, small piston must move
50cm to in order to raise the large
piston 10cm => Law of conservation of
energy.

Description/Location

Description/Location

Description/Location

Description/Location

Wind Turbine Hydraulic Oils

5 main tasks of hydraulic oil in the wind turbine;

To transfer hydraulic energy
To lubricate all parts
To avoid corrosion
To remove impurities and abrasion
To dissipate heat.
Physical properties to consider;
Viscosity index => increased viscosity at lower temps
Shear and thermal stability => longer service time
Usable temperature range
Usable pressure range
Detergency => prevents depositing of contaminants

Wind Turbine Hydraulic Oils

Viscosity is single most important selection factor for the

turbine hydraulic oil. Based on;
Starting viscosity at minimum ambient temperature
Maximum expected operating temperature, which is
influenced by maximum ambient temperature
Permissible and optimum viscosity range for the systems
components

Wind Turbine Hydraulic Oils

The gamesa turbine hydraulic group uses 1 of three hydraulic oil

types;
Texaco Rando HDZ 32

Minimum viscosity change over large temperature range

Meets all major pump manufacturer requirements
Fuchs Renolin HV1 32 GA
Shell Tellus T32
Mineral hydraulic oil
Suitable for ultra-fine filtration
315 L required for G8X Platform and expected service life is 5
years
Oil level alarm goes off at 130 to 140 L

Wind Turbine Hydraulic Oils

What happens if hydraulic oil is allowed to circulate at a high

temperature for a long period of time?
As temperature goes up, hydraulic oil viscosity goes down.
Low viscosity results in the failure of the oil to maintain a
lubricating film between the internal parts of the system.
1. Oil will need replacing as high temperature will have destroyed it.
2. Cylinder seals can be destroyed => expensive, downtime
3. Failure of hydraulic motor pistons => expensive
Imperative that high oil temperatures be avoided

Wind Turbine Hydraulic Oils

Water Contamination
Water contamination can affect the following
properites;
Viscosity
Lubrication capacity and load-carrying
characteristics.
Power transfer characteristics (compressibility).

Wind Turbine Hydraulic Filters and

Filtration Elements
Nacelle

Turbine hydraulic filter must meet the following

performance requirements;
Capable of reducing the initial contamination to desired level
within an acceptable period of time.
Must achieve and maintain level with a suitable safety factor.
Easily accessible for maintenance.
Must provide sufficient dirt-holding capacity for an acceptable
interval between element changes.
Must not produce undesirable effects on the
operation of components, such as high back
pressures.
Hub

Wind Turbine Hydraulic Filters and

Filtration Elements
3 microns

Generally reccomended that at least a 25 micron

(1 micron = 0.000039 inches) range be used for a
hydraulic system.
G8X platform uses a 10 micron filter and a 3 micron filter (1
red blood cell is 8 microns in diameter).
To satisfy performance requirements, must consider;
Degree of filtration
Flow rate
Pressure drop
Dirt capacity
System Pressure
Temperature
10 microns

Wind Turbine Hydraulic Filters and

Filtration Elements
G8X hydraulic system uses a pressure filter to
remove oil contamination.

Wind Turbine Hydraulic Filters and

Filtration Elements

Wind Turbine Hydraulic Filters and

Filtration Elements

Wind Turbine Hydraulic Filters and

Filtration Elements

Wind Turbine Hydraulic Filters and

Filtration Elements
G8X hydraulic system nacelle pressure filter and
hub pressure filter are changed every 12 months.
Each changed whenever the hydraulic oil is
replaced.
Nacelle filter changed if the fall in pressure
between the pressure sampling ports on either side
of the filter exceeds the values given in the
following table.

Pressure Sampling port

Wind Turbine Hydraulic Filters and

Filtration Elements
Indicators for hydraulic filter change
Pressure differences across the filtration element
If pressure is erratic in system then passage through
the filter is being restricted.
Very likely there is contamination in the hydraulic
fluid and hence the filter => replace filter.

Hydraulic Oil Temperature

Oil viscosity will breakdown and lubrication will be
less causing contamination of system and hence the
filters => replace filters along with oil

Wind Turbine Hydraulic Filters and

Filtration Elements

Flow and Pressure Control Valves

Flow Control Valves

Regulate flow or pressure of the hydraulic oil.
Respond to signals generated by devices such as flow
meters or temperature guages.

Pressue Control Valves

Limit maximum system pressure as a safety measure.
Unload system pressure.
Operate on balance between pressure and mechanical
load.
Valve can be fully opened depending on a pressure
differential.

Flow and Pressure Control Valves

Solenoid Valve:
Also called an electrochemical valve. 14 are
present in the hydraulic system (4 on each pitch block (12
total), 1 on rotor brake block, and 1 on yaw brake block).
Controls the flow of oil by opening and closing via an electric
current => similar to a light switch but for liquids.
If solenoid in E is activated by an electric current
it will raise and water from C will flow through D
and the pressure in C will be reduced and the
diaphragm will lift and oil will flow from A to F.
A- Input side
B- Diaphragm
C- Pressure chamber
D- Pressure relief conduit
E- Solenoid
F- Output side

Solenoid valve working

Flow and Pressure Control Valves

Needle valve (butterfly valve): flow control

valve. Can regulate flow very precisely. Until
needle is completely retracted, flow is
impeded significantly.
Pressure relief valve: used to control or limit
pressure in system. Prevents overloading. Once
system reaches reset pressure, the valve will close.
Pressure Relief Valve video
Check valve (anti return vavle): allows flow in only on direction.
Function like a heart valve. Allows the resevoir (accumulator) to
maintain pressure when system is inactive.

Flow and Pressure Control Valves

Indicators of pressure relief valve malfunction

Poor filtration can lead to damage of any valve in

the system.

Pumps/Motors, Cylinders, and

Accumulators

Pump/Motor System
Pump-motor sits on top of the resevoir
while the pump is located below inside
the resevoir.
Pump creates a minimum pressure of
180 bar and maximum pressure of
200 bar in the system.

Pumps/Motors, Cylinders, and

Accumulators
Turbine hydraulic pump is a positive
displacment type pump.
A relief valve will be located
after the high pressure outlet to regulate
pressure in system.
Turbine hydraulic system also contains a
relief valve after the high pressure
outlet to prevent cavitation in the circuit.

Cavitation: when fluid does not entirely fill the space

provided for it in the pump => air cavities which
implode when the encounter a high pressure area.

Pumps/Motors, Cylinders, and

Accumulators
Pump/Motor problems
Insufficient pressure
Relief valve not properly set.
Excessive pump noise
Pump-motor misalignment.
Low oil level.
Wrong oil type.
System Excessively hot
Pump operated at higher pressure than
required.
Inadequate cooling provided by cooling
system.
Oil low in resevoir => leaks.

Pumps/Motors, Cylinders, and

Accumulators

Single rod cylinders located in turbine hub

Pumps/Motors, Cylinders, and

Accumulators
Must limit the extension speed (pressure) of the cylinders.
Force in the cylinder is equal to pressure times the area.
If the pressure rating of the cylinder is for some reason
exceeded, the consequences can be serious.
Following video demonstrates cylinder function in a simple
hydraulic circuit as well as what can happen when the
pressure rating is exceeded when the flow is managed
incorrectly.
Single rod cylinder extension

Cylinder extension has a typical sound as does cylinder retraction.

Differences in sounds indicate some type of cylinder failure.

Pumps/Motors, Cylinders, and

Accumulators
Cylinder Failures/Problems
Cylinder seal malfunction
Improper installation
Hydraulic system contamination
Chemical breakdown of the seal => poor
seal selection
Heat degredation
Diesel effect air passes through seals and
mixes with hydaulic fluid and explodes when
pressurized.
Bent cylinder rods
Poor design => insufficient rod diamter
Improper cylinder mounting
Cylinder tube ballooning
Tube material unable to withstand operating pressure

Pumps/Motors, Cylinders, and

Accumulators

Principle accumulator 32 L
Rotor brake accumulator 4L (behind motor
in photo)
Principle rotor accumulator 20L (not seen)

3 Pitch accumulators 3.5L

Yaw accumulator 3.5L

Pumps/Motors, Cylinders, and

Accumulators

Functions as an energy storage device.

Held under pressure by an external source => nitrogen
Allows for system to cope with large demands => better than using a larger pump
System can respond quickly to temporary demand and smooth pulsations.

Pumps/Motors, Cylinders, and

Accumulators
PART REFERENCE:

DESCRIPTION:

Fluid Port Assembly

B6

Flanged Washer

B7

Locking Ring

B8

Bleed Adaptor

B9

Bleed Valve

C1

Shell

D1

Bladder

D2

Gas Valve Assembly

D3

Locknut

D4

Protective Cap

D5

O Ring

E1

Anti Extrusion Ring

E2

O Ring

E3

Bonded Seal

E4

Back-up Ring

Pumps/Motors, Cylinders, and

Accumulators
Bladder failure is one of the most common
accumulator problems.
Various types of bladder material cuts and
tears caused by; rapid precharging, little or
no precharging, folding of bladder bottom
during replacement, lack of lubrication on
the bladder
Fluid contamination can cause debris entrapment
between bladder and wall during cycling
=> good filtration necessary.
Gas valve leaking
Dirt can get into the gas valve stem keeping the valve core
from sealing.

Hydraulic Group General

Safety Considerations
Working with a large volume of oil
Spills
Eye/skin irritation

Working with high pressures

Spills
Possible explosion risks

Movement of pitch cylinders while doing preventive

maintance in the hub
Trapping
High pressures must be respected and the devices
handling the high pressures must be understood.

Hydraulic System Schematics

blade cylinder
retraction

membrane
block

rotor brake

blade cylinder
extension

blade cylinder
emergency

HUB

distributor block
yaw brake
Primary pump,
accumulator,
resevoir

cooling

NACE
LLE

Hydraulic System Schematics

Common Symbols

Continuous line (flow

line)

Circle As a rule, energy conversion units(pump, compressor,

motor

Squares As a rule, control valves (valve) except for non-return valves

Diamond Conditioning apparatus(filter, separator, lubricator, heat

exchanger
Restriction (affected by
viscosity)
Solid Direction of Hydraulic
Fluid
Pump One direction of
flow

Hydraulic System Schematics

Common Symbols

Sloping arrow -indication of the possibility of the regulation or a

progressive(proportional)variability.

Cylinder - Returned by unspecified force cylinder in which the fluid pressure always acts in one and the
same direction on the extension stroke.

Single square indicates a unit that controls flow or pressure (having an infinite number of possible positions that
would vary the conditions of flow across one or more of its ports, ensuring the chosen pressure and/or flow depending

on the operating conditions of the circuit)

Two squares indicates a directional control valve with two positions (would show flow paths through ports in actual application)

One flow path

Two closed ports

Two flow paths

Two flow paths and one closed port

Two position would have distinct circuit conditions shown in each

square

Free opens if the inlet pressure is higher than the outlet

pressure

Hydraulic System Schematics

Common Symbols

One normally closed throttling orifice (general

symbol)

Pressure relief
valve

Electric

motor

Accumulator - The fluid is maintained under pressure by a spring, weight or compressed gas
(air, nitrogen, etc.)

Filter

Not showing coolant flow the arrows indicate the extraction of

heat

Hydraulic symbol videos

Hydraulic System Schematics

Filling of Principle Accumulator
Positions 2, 5, 6, 7, 8 form the
pump motor group.
Position 22 is 3 micron pressure
filter.
Position 23 is a pressure
transductor that sends the actual
pressure to the PLC.
Postion 4 is an antireturn or check
valve to ensure that oil does not flow
back from the accumulator to the
pump.
Position 25 is a safety valve that
opens when 225 bar is reached and
returns oil to the tank.
9.1 is the system thermometer and
9.2 is the tank level detector.

Hydraulic System Schematics

Filling of Principle Accumulator

Hydraulic System Schematics

Filling of Principle Accumulator

Hydraulic System Schematics

Rotor Brake
Rotor brake system is supplied from the main
hydraulic group via a reduction valve.
Circuit passes through a check valve and loads the
brake accumulator and braking can be assured
without pressure from the principle accumulator or
the princple hub accumulator.

Hydraulic System Schematics

Rotor Brake

Hydraulic System Schematics

Rotor Brake

Hydraulic System Schematics

Yaw System Brake
Hydraulic system provides braking or clamping of
the yaw system in order to maintain its position
once set.
Similar to the rotor brake, yaw system has its own
accumlator which maintains pressure in the yaw
brake system.

Hydraulic System Schematics

Yaw System Brake

Hydraulic System Schematics

Yaw System Brake
102- ANTI-RETURN VALVE. ALLOWS
ENTERY OF THE OIL INTO THE YAW
CIRCUIT AND THE ACCUMULATOR IS
FILLED. THE VALVE NUMBER 103
SHOULD BE CLOSED.
104- VALVE TO LIMIT THE PRESSURE (230
bar)
105- WHERE THE PRESSURE OF THE
CIRCUIT IS MEASURED.
108- PRESSURE TRANSDUCTOR. IT
MEASURES THE PRESSURE IN THE
CLAMPS
WHEN THE TURBINE IS ORIENTING
ITSELF, THE VALVE 109 IS ACTIVATED.
VALVE 110 REDUCES THE PRESSURE TO
200 BAR (20 BAR)

Hydraulic System Schematics

Yaw System Brake

Rotating Joint

Connects the main hydraulic unit in the nacelle to the pitch

control hydraulic system in the rotor.
Rotor electrical equipment runs through this joint as well.
Composed of a high pressure line and a low pressure return line.
Connection between the pipes is mobile and the circuit leading
to the rotor is composed a double-channel rotating joint fitted
behind the gearbox.
PS channel (3/4 inch): pressure channel from hydraulic group
TS channel (1 inch): return channel for oil return.
DS channel (1/2 inch): drainage channel to reconduct leaks.
Electrical channel (18 mm): carries electrical cables.

Rotating Joint

Rotating Joint

Two hydraulic
lines and one
electrical line enter
into the hub from
the rotating joint.

Distributor Block and Membrane

Block

Distributor block feeds pitch system.

Membrane block is inactive until there is a blockage
in return line through rotating joint.
In this event, circuit is directed to membrane block
and oil sent to a resevoir.

Hydraulic System Schematics Distributor Block

Located in hub in order to

reduce the distance travelled
through the rotating joint.
Acumulator (pos 74) at
143 bar
From here, pressure will move
to the pitch system hydraulics
10 micron filter is used in this
block in order to avoid
contamination that may enter from
the rotating joint

Hydraulic System Schematics Distributor Block

Membrane Block

4 lines connecting to drainage tank, 1 giving

oil in the event of blockage in the line and
1 from the return from each cylinder
in the event of blockage in the rotating joint.

Hydraulic System Schematics MEMBRANE BLOCK

Only used when blockage in the

the rotating joint is detected.
When blockage occurs, membrane
in position 76 breaks and oil flows to
70 L overflow tank (postion 51)
4 lines lead into overflow tank from
block
1 from blockage in the rotating
joint.
3 from each cylinder in the pitch
system

Hydraulic System Schematics Membrane Block

Blade Pitch Control

Main parts of the pitch control system hydraulic circuit;

Multiple distributor block => contains the valves that control

the movement of each cylinder.
3 accumulators for each block as well as one principle
accumulator (in distributor block) for entire pitch control system.
Membrane block that, in the event of a rotating joint blockage
on the return line from pitch system, sends the oil to
a storage tank.
The function of the block is to maintain
a circuit so as to prevent rupture in
the principle circuit.
Proportional valve controls cylinder, depending
on the recieved operation signal.

Blade Pitch Control

Blade Pitch Control

Extension or retraction of the

cylinder will rotate the blade
between ~0 degrees and 90
degrees (with respect to the
tower).

Blade Pitch Control Proportional

Valve
Controlled by electronic control boards.
Sometimes called electro-hydraulics.
Can control direction and the amount of fluid or can
control the amount of pressure in a system.
Useful in situations;
Where system speed must be tightly controlled.
Where ramping up and down is needed to avoid
sudden stops and starts.
When precise control of hydraulic pressure build up is
necessary.

Blade Pitch Control Proportional

Valve
Valve works on the
principle of double
feedback control.
Feedback comes
from valve itself
(position) and from
balluf (cylinder
position).

Blade Pitch Control Proportional

Valve

Normal Flow
Cylinder Extension

No flow - Emergency

Proportional valve function

Flows criss-crossed
Cylinder Retraction

PITCH SYSTEM
CASE 1: Cylinder Retraction

Oil enters and follows circuit

in red (pressurized) and flows
out of system (blue)
Retraction circuit is activated
upon activation of the
proportional valve at postion 82.
Anti return valve at postion 96
does not function as oil flows
in the opposite direction the valve
will function in.

PITCH SYSTEM
CASE 2: Cylinder Extension

For cylinder extenstion, oil is

recycled through proportional
valve.
Anti return valve at position 96
forces oil back to postion 84.2 and
oil is recirculated.

PITCH SYSTEM
CASE 3: Emergency

When in emergency, valves 82, 83.2,

and 83.1 all close.
Solenoid valves at 81.2 and 81.1 open.
Load control valve at position 90 then comes
into contact with pressurized oil.
This valve ensures there is enough pressure
to counter act the force of the wind while in
emergency.

Hydraulic System Schematics Pitch System

Hydraulic System Schematics Pitch System

81.1, 81.2
Energized = no flow
De-energized = allow flow

83.1, 83.2
Energized = allow flow
De-energized = no flow

Accumulator 87 ensures there is

sufficient oil to pitch blades to 90 as
24 and 74 will be discharged.
Accumulator 94 absorbs pressure
shocks from valve 90.
Accumlator 93 delivers pressure
to return oil when in emergency.

Hydraulic System Schematics Pitch System

Hydraulic System Schematics Pitch System

Hydraulic System Schematics Pitch System

Hydraulic System Maintenance

General
Considerations/Comments
Very robust design.
System is always running between 180 and 200 bar
200 bar
180 bar

time

When there is no pressure in the system, first step

in determining cause is to start system and listen.
Air filter for cooling system must remain clean.
Holes in system can only knock out pressure if they
occur in certain areas.

Hydraulic System Maintenance

General
Considerations/Comments
One very good method to detect turbine hydraulic problems
=> remote monitoring of turbine hydraulic systems.
e.g. if one turbine in the park is running an oil temperature
of 56 C and the rest are running at 42 C..
Due to electrical control of solenoid and proportional valves,
often times a hydraulic problem is often in reality an electrical
problem.
Proportional valves and solenoid valves are electrical as well
as hydraulic so care must be taken when working with them
=> cut current to them.
So far there has been no case of hydraulic hosing breaking in
field.

Hydraulic System Maintenance

General
Considerations/Comments
In Vestas turbines, the yaw brake is an completely
separate hydraulic system.
Yaw hydrualic block is the same in both G5X and
G8X turbines.
6mm steel tubing from yaw block is very
resistant against high pressures but can
be easily damaged by outside
mechanical force => someones foot!

Hydraulic System Maintenance

Common
Problems/Troubleshooting/Solutions

Dont change the oil, filter it.

Water or particle contamination rarely necessitates
an oil change unless it results in additive depletion
or base oil degredation.
If the oil maintains its chemical and viscoelastic
integrity, then the filter should take care of all
contamination
so long as the filter is properly maintained.

Hydraulic System Maintenance

Common
Problems/Troubleshooting/Solutions
Eliminate particle contamination to reduce breakdowns.
ISO 4406 is a measure of hydraulic fluid cleanlinesss.

Research has shown that an

ISO 4406 level of 16/14/11
will result in a tenfold decrease
in average time between
breakdowns when compared to a
level of 24/22/19 (3 year study)

Hydraulic System Maintenance

Common
Problems/Troubleshooting/Solutions

Particle contamination reduces fluid life by stripping

additives and promoting oxidation.
Additives attach to particles with then are removed
by filtration or settle to the bottom of the resevoir.
Worn metal can act as a catalyst for fluid oxidation.
Keep the fluid cool.
High temperatures promote fluid oxidation.
Oxidation products such as varnish and sludge can
plug filters and valves.

Hydraulic System Maintenance

Common
Problems/Troubleshooting/Solutions
6 routines must be followed in order to minimize hydraulic system failure;
Maintain fluid cleanliness
Maintain fluid temperature and viscosity within optimum limits
Maintain hydraulic system settings to manufacturers specifications
Schedule component change-outs before they fail
Follow correct commissioining procedures
Conduct failure analysis.

Effective program requires time, effort

and expense but is cost effective =>
investment is quickly recovered!

Hydraulic System Maintenance

Common
Problems/Troubleshooting/Solutions

Safety bulletin