Quellmoor Ridge O&M wiki

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gearbox

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FICTIONAL SAMPLE - Contoso Renewables, Quellmoor Ridge Wind Farm and every organisation, person, product and value in this wiki are invented. Not for operational use.

A gearbox is a component used in LT-32 turbines and in the Fabrikam FGT-3200 three-stage gearbox.12 The LT-32 gearbox has an overall ratio of 1:118.4, a rated input torque of 2,410 kNm, and a dry mass of 21.6 t.2 Its lubrication system uses splash and forced lubrication, and the total oil volume is 410 L.23

Facts

  • The bulletin is categorized as recommended, but mandatory to keep the gearbox warranty.4
  • The gearbox must be flushed with 60 L of PWG 220, the electric oil pump run for 30 minutes, and the flush oil then drained.4
  • The gearbox must be filled with 410 L of PWG 220 through a filter cart with a 10 micron element.4
  • The gearbox filler must be labelled 'PWG 220' using the supplied label kit.4
  • Conversions performed according to the bulletin keep the gearbox warranty valid.5
  • The excerpt is Chapter 4, Gearbox, of document LWS-MM-GBX-32 Rev. D, issued by Litware Wind Systems on 2024-03-15.1
  • The document applies to LT-32 turbines of all variants with the Fabrikam FGT-3200 gearbox.1
  • Gearbox work requires the turbine to be stopped, the rotor locked, and the drivetrain isolated according to the operator's lockout procedure; hot oil up to 80 °C can cause burns.1
  • Litware Wind Systems publishes changes to the gearbox chapter as service bulletins, and the bulletin register must be checked before planning gearbox work.1
  • The LT-32 uses a Fabrikam FGT-3200 three-stage gearbox with one planetary stage followed by two parallel helical stages.2
  • The gearbox overall ratio is 1:118.4; at a rated rotor speed of 12.7 rpm, the output pinion shaft drives the generator at 1,500 rpm.2
  • The FGT-3200 gearbox rated input torque is 2,410 kNm and its dry mass is 21.6 t.2
  • The gearbox lubrication system uses splash and forced lubrication, with a shaft-driven pump for operation and an electric pump for start-up and flushing.2
  • Only the lubricant listed in Table 4-2 is approved for the FGT-3200 gearbox, and lubricants of different brands or viscosity grades must not be mixed.3
  • The total oil volume is 410 L, made up of 330 L in the gearbox sump and 80 L in the cooling and filter circuit.3
  • Alarm A2101, Gearbox oil sump temperature high at 75 °C, can be caused by cooling, oil level, load/ambient-temperature, or bearing issues; actions include checking fan rotation and motor current, cleaning the radiator, checking valve insert LWS-P-30422, checking oil level, reviewing vibration trend, and taking an oil sample.6
  • Alarm A2102, Gearbox oil sump temperature trip at 82 °C, stops the turbine automatically; the cooling circuit is inspected before restart, and reset is not performed more than once without inspection.6
  • Alarm A2110, Gearbox HSS bearing temperature high at 90 °C, can be caused by bearing damage or lubrication starvation; checks are vibration trend review and endoscope inspection of the bearing.6
  • Alarm A2120, Gearbox oil pressure low at 0.8 bar, can be caused by cold oil at start-up, pump fault, or blocked filter; actions are to allow heater time at cold start and check the pump and filter.6
  • Alarm A2140, Gearbox oil filter differential pressure high at 2.5 bar, can be caused by a clogged filter element or cold oil; the action is to replace filter element FGT-P-11872.6
  • The bulletin makes the oil-grade change a condition of the gearbox warranty.7
  • The report is oil analysis report TR-OA-2026-0614 for gearbox oil from WTG-07 at Quellmoor Ridge.8
  • The asset is the WTG-07 main gearbox, a Fabrikam FGT-3200 with serial FGT-3200-18-07752.8
  • The procedure is intended to change gearbox oil safely and avoid contaminating the new oil.9
  • The scope covers all gearbox oil changes on WTG-01 to WTG-12, including planned changes and changes decided after oil analysis.10
  • The spill kit must be ready at the gearbox, with absorbent pads under every connection.11
  • The gearbox sump and the cooling and filter circuit are drained into waste containers, with an approximate drained volume of 410 L.12
  • The gearbox is filled with 410 L of Proseware PWG 220 through a 10 micron filter cart.13
  • Controller parameter GBX_TMIN_START must be set to 5 °C, and the gearbox filler must be labelled PWG 220.14
  • A converted gearbox must never be topped up with PWG 320, and residual PWG 320 must remain below 5 % of oil volume.15
  • The incident concerns WTG-07, serial LT32-19-0421, with gearbox FGT-3200-18-07752.16
  • WTG-09 has gearbox oil conversion to PWG 220 pending and deferred under SB-LWS-2025-07.17
  • Gearbox oil sampling and laboratory analysis task MP-GBX-01 is scheduled every 6 months, with a duration field of 1 h and crew field of 1.18
  • Gearbox oil filter element replacement task MP-GBX-02 uses part FGT-P-11872, is scheduled every 12 months, and references SOP-GBX-010.19
  • Gearbox oil change task MP-GBX-03 for PWG 220 is scheduled every 5 years or on condition, references SOP-GBX-010 Rev. B, has a duration field of 6 h, and notes that the next planned changes start from 2030.20
  • In the Plan 2026 sheet, WTG-02 gearbox endoscope inspection task MP-GBX-04 is planned for 2026-07 and has status done at 2026-07-01.21
  • SPL-012 is titled "Gearbox oil level check."22
  • To check the gearbox oil level, stop the turbine and wait 20 minutes so the oil settles.23
  • Read the sight glass on the generator side of the gearbox.23
  • The gearbox oil level must be between MIN and MAX.23
  • Record the gearbox oil level check result on item 4 of the daily checklist.23
  • On 2026-04-02, WTG-08 and WTG-09 raised A2120 Gearbox oil pressure low at 0.59 bar and later cleared at 1.35 bar.24252627
  • On 2026-05-30, WTG-07 raised A2101 Gearbox oil sump temperature high at 75.3 °C, then raised A2102 Gearbox oil sump temperature trip at 82.6 °C and entered S510 Stopped - fault.282930
  • On 2026-06-19, WTG-07 first raised A2101 Gearbox oil sump temperature high at 75.6 °C, then raised A2102 Gearbox oil sump temperature trip at 83.4 °C and entered S510 Stopped - fault.313233
  • WTG-02 recorded A2110 Gearbox HSS bearing temperature high twice in this part, with raised values of 91.2 °C on 2026-07-19 and 90.6 °C on 2026-07-22.3435
  • WTG-12 raised A2140 Gearbox oil filter differential pressure high at 2.56 bar on 2026-08-02 and cleared it at 1.90 bar later the same day.3637
  • WTG-04 raised A2140 Gearbox oil filter differential pressure high at 2.89 bar on 2026-08-11 17:18:08 and cleared it at 1.90 bar on 2026-08-11 18:22:08.3839
  • WTG-11 raised A2101 Gearbox oil sump temperature high at 75.1 °C on 2026-08-12 16:05:02 and cleared it at 72.7 °C on 2026-08-12 16:14:40.4041
  • WTG-06 had A2140 Gearbox oil filter differential pressure high raised at 2.89 bar and cleared at 1.90 bar on 2026-08-31.4243
  • The export records a completed high-priority modification campaign for gearbox oil conversion from PWG 320 to PWG 220 with a 60 L flush for WTG-01 through WTG-12 under reference MOC-2025-012; each row lists part PWS-220-D208 with quantity 3.444546474849505152535455
  • The WTG-09 gearbox oil conversion work order WO-25-0309 was deferred because the access road was closed by snow on 2025-11-24 and was completed on 2026-01-20.52
  • Gearbox oil sampling work orders WO-26-0341 through WO-26-0352 cover WTG-01 through WTG-12 and are all marked Completed.565758596061626364656667
  • The deck is titled “Gearbox fundamentals for wind technicians.”68
  • The gearbox raises rotor speed from 12.7 rpm to 1,500 rpm at the generator.69
  • The gearbox stages described are a planetary stage with a planet carrier, three planet gears, a ring gear and a sun pinion, followed by two parallel helical stages.70
  • The overall gearbox ratio is 1:118.4, with rotor speed 12.7 rpm and generator speed 1,500 rpm.70
  • Each gearbox uses 410 L of oil, with a 60 L flush during the conversion.71
  • Typical gearbox-related failure modes listed are HSS bearing damage, micropitting on gear teeth, cooler fouling and fan motor failures, and oil leaks at seals and hoses.72
  • WTG-07 availability was 95.2 % because of gearbox trips.73
  • 8D INC-2026-006 was opened on 2026-05-30 for the WTG-07 gearbox over-temperature issue.74
  • Litware’s response addresses a 29 April 2025 question about SB-LWS-2025-07 Rev. A, described as covering gearbox oil viscosity grade for CCV turbines.75
  • Each gearbox is to be flushed with 60 L of PWG 220 before the final fill of 410 L.76
  • Conversions made according to the bulletin keep the gearbox warranty valid.77
  • For A2120 gearbox oil pressure low immediately after a cold start, technicians should give the heaters more time before escalating, because it is usually cold oil rather than a pump fault.78
  • After conversion, a gearbox must never be topped up with PWG 320; old PWG 320 drums are marked do not use.79
  • Superseded: The procedure describes how to change gearbox oil on Quellmoor Ridge turbines safely and without contaminating the new oil.80
  • Superseded: The scope covers all gearbox oil changes on WTG-01 to WTG-12, whether planned or decided after oil analysis.81
  • Superseded: The spill kit must be kept ready at the gearbox, with absorbent pads under every connection.82
  • Superseded: The gearbox sump and cooling and filter circuit are drained into waste containers, with an approximate drained volume of 410 L.83

Timeline

  • 2024-03-15: The excerpt is Chapter 4, Gearbox, of document LWS-MM-GBX-32 Rev. D, issued by Litware Wind Systems on 2024-03-15.1
  • 2025-04-29: Litware’s response addresses a 29 April 2025 question about SB-LWS-2025-07 Rev. A, described as covering gearbox oil viscosity grade for CCV turbines.75
  • 2025-07: WTG-09 has gearbox oil conversion to PWG 220 pending and deferred under SB-LWS-2025-07.17
  • 2025-11-24: The WTG-09 gearbox oil conversion work order WO-25-0309 was deferred because the access road was closed by snow on 2025-11-24 and was completed on 2026-01-20.52
  • 2026-04-02: On 2026-04-02, WTG-08 and WTG-09 raised A2120 Gearbox oil pressure low at 0.59 bar and later cleared at 1.35 bar.24252627
  • 2026-05-30: 8D INC-2026-006 was opened on 2026-05-30 for the WTG-07 gearbox over-temperature issue.74
  • 2026-05-30: On 2026-05-30, WTG-07 raised A2101 Gearbox oil sump temperature high at 75.3 °C, then raised A2102 Gearbox oil sump temperature trip at 82.6 °C and entered S510 Stopped - fault.282930
  • 2026-06-19: On 2026-06-19, WTG-07 first raised A2101 Gearbox oil sump temperature high at 75.6 °C, then raised A2102 Gearbox oil sump temperature trip at 83.4 °C and entered S510 Stopped - fault.313233
  • 2026-07: In the Plan 2026 sheet, WTG-02 gearbox endoscope inspection task MP-GBX-04 is planned for 2026-07 and has status done at 2026-07-01.21
  • 2026-07-19: WTG-02 recorded A2110 Gearbox HSS bearing temperature high twice in this part, with raised values of 91.2 °C on 2026-07-19 and 90.6 °C on 2026-07-22.3435
  • 2026-08-02: WTG-12 raised A2140 Gearbox oil filter differential pressure high at 2.56 bar on 2026-08-02 and cleared it at 1.90 bar later the same day.3637
  • 2026-08-11: WTG-04 raised A2140 Gearbox oil filter differential pressure high at 2.89 bar on 2026-08-11 17:18:08 and cleared it at 1.90 bar on 2026-08-11 18:22:08.3839
  • 2026-08-12: WTG-11 raised A2101 Gearbox oil sump temperature high at 75.1 °C on 2026-08-12 16:05:02 and cleared it at 72.7 °C on 2026-08-12 16:14:40.4041
  • 2026-08-31: WTG-06 had A2140 Gearbox oil filter differential pressure high raised at 2.89 bar and cleared at 1.90 bar on 2026-08-31.4243

Documents

Sources

Footnotes

  1. LWS-MM-GBX-32 Rev. D — LT-32 Maintenance Manual Chapter 4 Gearbox Excerpt — p. 1 · ✓ quote verified ↩ ↩2 ↩3 ↩4 ↩5 ↩6

  2. LWS-MM-GBX-32 Rev. D — LT-32 Maintenance Manual Chapter 4 Gearbox Excerpt — p. 2 · ✓ quote verified ↩ ↩2 ↩3 ↩4 ↩5 ↩6 ↩7

  3. LWS-MM-GBX-32 Rev. D — LT-32 Maintenance Manual Chapter 4 Gearbox Excerpt — p. 3 · ✓ quote verified ↩ ↩2 ↩3

  4. SB-LWS-2025-07 Rev. A - Gearbox oil viscosity grade change for LT-32 CCV turbines — p. 1 · ✓ quote verified ↩ ↩2 ↩3 ↩4

  5. SB-LWS-2025-07 Rev. A - Gearbox oil viscosity grade change for LT-32 CCV turbines — p. 2 · ✓ quote verified ↩

  6. LWS-MM-GBX-32 Rev. D — LT-32 Maintenance Manual Chapter 4 Gearbox Excerpt — p. 5 · ✓ quote verified ↩ ↩2 ↩3 ↩4 ↩5

  7. MOC-2025-012 - Gearbox Oil Grade Change to PWG 220 — ¶ 6 · ✓ quote verified ↩

  8. Oil analysis report TR-OA-2026-0614 - WTG-07 gearbox oil — p. 1 · ✓ quote verified ↩ ↩2

  9. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 5 · ✓ quote verified ↩

  10. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 7 · ✓ quote verified ↩

  11. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 20 · ✓ quote verified ↩

  12. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 30 · ✓ quote verified ↩

  13. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 35 · ✓ quote verified ↩

  14. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 38 · ✓ quote verified ↩

  15. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 42 · ✓ quote verified ↩

  16. 8D report INC-2026-006 - Repeated gearbox oil over-temperature on WTG-07 (revision 2026-07-10) — table 1, row 3 · table ↩

  17. Asset Register 2026 of Quellmoor Ridge Wind Farm, revision 2026-01-12 — sheet "Turbines", row 10 · table ↩ ↩2

  18. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Tasks", row 2 · table ↩

  19. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Tasks", row 3 · table ↩

  20. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Tasks", row 4 · table ↩

  21. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Plan 2026", row 19 · table ↩ ↩2

  22. SPL-012 Gearbox Oil Level Check — slide 1 · ✓ quote verified ↩

  23. SPL-012 Gearbox Oil Level Check — slide 2 · ✓ quote verified ↩ ↩2 ↩3 ↩4

  24. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 32 · table ↩ ↩2

  25. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 33 · table ↩ ↩2

  26. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 34 · table ↩ ↩2

  27. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 35 · table ↩ ↩2

  28. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 550 · table ↩ ↩2

  29. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 551 · table ↩ ↩2

  30. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 552 · table ↩ ↩2

  31. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 946 · table ↩ ↩2

  32. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 947 · table ↩ ↩2

  33. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 948 · table ↩ ↩2

  34. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1330 · table ↩ ↩2

  35. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1366 · table ↩ ↩2

  36. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1436 · table ↩ ↩2

  37. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1485 · table ↩ ↩2

  38. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1654 · table ↩ ↩2

  39. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1655 · table ↩ ↩2

  40. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1660 · table ↩ ↩2

  41. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1661 · table ↩ ↩2

  42. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1896 · table ↩ ↩2

  43. SCADA alarm and status log, 2026-04-01 to 2026-08-31 — row 1897 · table ↩ ↩2

  44. Work Orders Export through 2026-08-31 — row 2 · table ↩

  45. Work Orders Export through 2026-08-31 — row 3 · table ↩

  46. Work Orders Export through 2026-08-31 — row 4 · table ↩

  47. Work Orders Export through 2026-08-31 — row 5 · table ↩

  48. Work Orders Export through 2026-08-31 — row 6 · table ↩

  49. Work Orders Export through 2026-08-31 — row 7 · table ↩

  50. Work Orders Export through 2026-08-31 — row 8 · table ↩

  51. Work Orders Export through 2026-08-31 — row 9 · table ↩

  52. Work Orders Export through 2026-08-31 — row 10 · table ↩ ↩2 ↩3

  53. Work Orders Export through 2026-08-31 — row 11 · table ↩

  54. Work Orders Export through 2026-08-31 — row 12 · table ↩

  55. Work Orders Export through 2026-08-31 — row 13 · table ↩

  56. Work Orders Export through 2026-08-31 — row 56 · table ↩

  57. Work Orders Export through 2026-08-31 — row 57 · table ↩

  58. Work Orders Export through 2026-08-31 — row 58 · table ↩

  59. Work Orders Export through 2026-08-31 — row 59 · table ↩

  60. Work Orders Export through 2026-08-31 — row 60 · table ↩

  61. Work Orders Export through 2026-08-31 — row 61 · table ↩

  62. Work Orders Export through 2026-08-31 — row 62 · table ↩

  63. Work Orders Export through 2026-08-31 — row 63 · table ↩

  64. Work Orders Export through 2026-08-31 — row 64 · table ↩

  65. Work Orders Export through 2026-08-31 — row 65 · table ↩

  66. Work Orders Export through 2026-08-31 — row 66 · table ↩

  67. Work Orders Export through 2026-08-31 — row 67 · table ↩

  68. Gearbox Fundamentals for Wind Technicians — slide 1 · ✓ quote verified ↩

  69. Gearbox Fundamentals for Wind Technicians — slide 2 · ✓ quote verified ↩

  70. Gearbox Fundamentals for Wind Technicians — slide 3 · ✓ quote verified ↩ ↩2

  71. Gearbox Fundamentals for Wind Technicians — slide 5 · ✓ quote verified ↩

  72. Gearbox Fundamentals for Wind Technicians — slide 8 · ✓ quote verified ↩

  73. Monthly O&M Review Minutes – 2026-06-18 — ¶ 8 · ✓ quote verified ↩

  74. Monthly O&M Review Minutes – 2026-06-18 — ¶ 10 · ✓ quote verified ↩ ↩2

  75. Email RE: LWS-TS-48213 Applicability of SB-LWS-2025-07 Rev. A to Quellmoor Ridge — message body, lines 5–6 · ✓ quote verified ↩ ↩2

  76. Email RE: LWS-TS-48213 Applicability of SB-LWS-2025-07 Rev. A to Quellmoor Ridge — message body, lines 16–23 · ✓ quote verified ↩

  77. Email RE: LWS-TS-48213 Applicability of SB-LWS-2025-07 Rev. A to Quellmoor Ridge — message body, lines 25–26 · ✓ quote verified ↩

  78. Toolbox Talk: Cold-Weather Start-Up After PWG 220 Conversion — 01:23–01:34 · ✓ quote verified ↩

  79. Toolbox Talk: Cold-Weather Start-Up After PWG 220 Conversion — 02:45–02:55 · ✓ quote verified ↩

  80. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 4 · ✓ quote verified ↩

  81. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 6 · ✓ quote verified ↩

  82. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 17 · ✓ quote verified ↩

  83. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 27 · ✓ quote verified ↩

Provenance badges✓ quote verified the quoted words were found verbatim in the source texttable values parsed deterministically from the cited table rows

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