Full System Inspection & Diagnostic Testing
Pitch rams must operate with precision, speed, and reliability, often under significant pressure, vibration, and temperature changes. Any malfunction such as internal leakage, loss of hydraulic pressure, bent rods, or sensor faults can reduce blade control accuracy or stop blade movement entirely.
Before replacement, we conduct a thorough inspection of the pitch system to confirm:
- Hydraulic fluid condition (signs of contamination or breakdown)
- Rod seal integrity and visible signs of leakage
- Physical damage such as bent rods or corroded surfaces
- Control system fault codes related to blade actuation
- Cylinder pressure performance, timing, and synchronization
This step ensures the fault is correctly identified, and no secondary components are damaged or misconfigured.
Safe Removal of Faulty Pitch Rams
Replacing a pitch ram requires a strict safety approach due to:
- High hydraulic pressures
- Confined workspace within the hub
- Proximity to electrical systems and control sensors
- Blade lockout procedures to prevent accidental movement
- Our technicians are fully trained in Lock-out/tag-out (LOTO) procedures
- Blade locking and stabilization
- High-pressure fluid system safety
- Confined space and working-at-height safety protocols
Using specialized tools and lifting equipment, the defective pitch ram is removed with care to avoid damaging nearby components such as pitch bearings, sensors, or hydraulic hoses.
Precision Installation of New Pitch Rams
Once the faulty unit is removed, we install a new or reconditioned OEM-compliant pitch ram, ensuring:
- Correct mounting torque and alignment
- Clean, contamination-free hydraulic connections
- Secure sensor and feedback loop integration (if applicable)
- Compatibility with existing pitch system software and firmware
Hydraulic Testing & System Calibration
- Hydraulic pressure tests to verify seal integrity and pressure response
- Motion range and timing checks to ensure smooth and synchronized blade movement
- Control system calibration using OEM tools to reset blade angle references
- Redundant testing to simulate feathering and emergency pitch-out conditions
This step ensures the entire system is operating as expected and that the new ram integrates seamlessly with the turbine’s SCADA and control systems.
Detailed Reporting & Documentation
- Service log with serial numbers, part references, and technician notes
- Inspection photos and videos (if needed)
- Pressure and performance test results
- Recommendations for further maintenance or follow-up inspection