SOP-GBX-010 - Gearbox oil change, Revision A

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Superseded by SOP-GBX-010 Rev. B - Gearbox oil change. Use the current revision.

This standard operating procedure describes the safe gearbox oil change process for Quellmoor Ridge turbines. It covers scope, references, safety requirements, materials and tools, step-by-step work instructions, waste handling, records, and revision history.

Key facts

• SOP-GBX-010 is a standard operating procedure, Revision A, effective 2023-04-03.¹²³⁴
• The procedure applies to WTG-01 to WTG-12, specified as Litware LT-32 CCV turbines with Fabrikam FGT-3200 gearboxes.⁵
• The procedure describes how to change gearbox oil on Quellmoor Ridge turbines safely and without contaminating the new oil.⁶
• The scope covers all gearbox oil changes on WTG-01 to WTG-12, whether planned or decided after oil analysis.⁷
• Referenced documents include LWS-MM-GBX-32 Rev. D section 4.3, SOP-LOTO-001, SOP-WAH-003, and oil level check at the sight glass.⁸
• A PTW is required, and at least two technicians are required with no lone working in the nacelle.⁹
• The turbine must be isolated according to SOP-LOTO-001 before the oil circuit is opened.¹⁰
• The job must not start if the 10-minute mean wind speed exceeds 15 m/s.¹¹
• For hot oil work, technicians must wear chemical gloves, face shield, and long sleeves, and draining is allowed only between 40 and 60 °C.¹²
• The spill kit must be kept ready at the gearbox, with absorbent pads under every connection.¹³
• The specified new oil is Proseware PWG 320 (ISO VG 320), with 410 L per turbine supplied as 2 drums PWS-320-D208.¹⁴
• One oil filter element FGT-P-11872 is required.¹⁵
• Required tools and containers include a filter cart with 10 micron element, transfer pump, three 200 L waste oil containers, a torque wrench covering 20 to 300 Nm, and oil sample bottles.¹⁶¹⁷
• The work starts by obtaining the PTW, stopping the turbine, and applying lockout/tagout according to SOP-LOTO-001 with the rotor locked and drivetrain isolated.¹⁸
• Oil temperature must be checked, draining must be between 40 and 60 °C, and if the oil is colder the heaters and electric oil pump are to be run before isolation.¹⁹
• A used-oil sample must be taken at the sampling valve for the laboratory.²⁰
• The gearbox sump and cooling and filter circuit are drained into waste containers, with an approximate drained volume of 410 L.²¹
• The magnetic plug is removed, debris is recorded, and the plug is cleaned.²²
• The FGT-P-11872 filter element is replaced, and the filter housing cover screws are tightened to 85 Nm.²³
• The drain plug is refitted with a new seal and tightened to 280 Nm.²⁴
• 410 L of Proseware PWG 320 is filled through a 10 micron filter cart.²⁵
• The electric oil pump is run for 15 minutes, after which all connections are checked for leaks.²⁶
• After 20 minutes of standstill, the oil level is checked at the sight glass and topped up if needed.²⁷
• After lockout removal and restart, oil temperature is watched during the first hour, and the turbine starts only when the oil sump has reached +10 °C.²⁸
• A reference oil sample is taken after 24 hours of operation.²⁹
• Quantities and batch numbers must be recorded in the work order.³⁰
• Waste oil is sent to the bunded store in the O&M building and collected by the licensed carrier, and oil sample results are kept with the work order.³¹
• Revision A is the first issue and is associated with PWG 320.³²

Contents

Document control

The document is titled “SOP-GBX-010 - Gearbox oil change.”³³ It is a standard operating procedure, Revision A, effective 2023-04-03.³⁴ The owner is Dario Penwarden, O&M Supervisor, and the approver is Maren Ellingsby, Site Manager.³⁵³⁶ It applies to WTG-01 to WTG-12, described as Litware LT-32 CCV turbines with Fabrikam FGT-3200 gearboxes.⁵

Table t01 · table 1, rows 1–7

Row	Field	Value
2	Document number	SOP-GBX-010
3	Revision	A
4	Effective date	2023-04-03
5	Owner	Dario Penwarden, O&M Supervisor
6	Approved by	Maren Ellingsby, Site Manager
7	Applies to	WTG-01 to WTG-12 (Litware LT-32 CCV, Fabrikam FGT-3200 gearbox)

Agents can query this table as t01 with the query_table tool.

Purpose

The procedure describes how to change the gearbox oil of the Quellmoor Ridge turbines safely and without contaminating the new oil.³⁷

Scope

The scope covers all gearbox oil changes on WTG-01 to WTG-12, whether the work is planned or decided after oil analysis.³⁸

References

The listed references are LWS-MM-GBX-32 Rev. D section 4.3, SOP-LOTO-001, SOP-WAH-003, and oil level check at the sight glass.^8394041

Safety

• A PTW is required, at least two technicians are required, and lone working in the nacelle is prohibited.⁴²
• The turbine must be isolated according to SOP-LOTO-001 before the oil circuit is opened.⁴³
• The job must not start if the 10-minute mean wind speed exceeds 15 m/s.⁴⁴
• For hot oil, chemical gloves, face shield, and long sleeves are required, and draining is only between 40 and 60 °C.⁴⁵
• The spill kit must be ready at the gearbox, and absorbent pads must be placed under every connection.⁴⁶

Materials and tools

• The specified oil is Proseware PWG 320 (ISO VG 320), 410 L per turbine, supplied as 2 drums PWS-320-D208.⁴⁷
• One oil filter element FGT-P-11872 is required.⁴⁸
• Required equipment includes a filter cart with 10 micron element, transfer pump, and 3 waste oil containers of 200 L.⁴⁹
• Required tools and sampling items include a torque wrench covering 20 to 300 Nm and oil sample bottles.⁵⁰

Procedure

• Obtain the PTW, stop the turbine, and apply lockout/tagout according to SOP-LOTO-001 with the rotor locked and drivetrain isolated.⁵¹
• Check oil temperature and drain only between 40 and 60 °C; if colder, run the heaters and electric oil pump before isolation.⁵²
• Take a used-oil sample at the sampling valve for the laboratory.⁵³
• Drain the gearbox sump and cooling and filter circuit into waste containers, about 410 L.⁵⁴
• Remove the magnetic plug, record debris, and clean the plug.⁵⁵
• Replace filter element FGT-P-11872 and tighten filter housing cover screws to 85 Nm.⁵⁶
• Refit the drain plug with a new seal and tighten it to 280 Nm.⁵⁷
• Fill 410 L of Proseware PWG 320 through the 10 micron filter cart.⁵⁸
• Run the electric oil pump for 15 minutes and check all connections for leaks.⁵⁹
• After 20 minutes of standstill, check the level at the sight glass and top up if needed.⁶⁰
• Remove lockout, restart, and watch oil temperature during the first hour; the turbine starts only when the oil sump has reached +10 °C.⁶¹
• Take a reference oil sample after 24 hours of operation.⁶²
• Record quantities and batch numbers in the work order.⁶³

Waste and records

Waste oil goes to the bunded store in the O&M building and is collected by the licensed carrier.⁶⁴ Oil sample results are kept with the work order.⁶⁴

Revision history

Revision A dated 2023-04-03 is the first issue and refers to PWG 320.³²

Table t02 · table 2, rows 1–2

Row	Revision	Date	Change
2	A	2023-04-03	First issue (PWG 320).

Agents can query this table as t02 with the query_table tool.

Figures

No figures were extracted from this document.

Related

• Assets: Quellmoor Ridge O&M building, Quellmoor Ridge Wind Farm, WTG-01, WTG-02, WTG-03, WTG-04, WTG-05, WTG-06, WTG-07, WTG-08, WTG-09, WTG-10, WTG-11, WTG-12
• Components: gearbox, gearbox oil heater, oil filter element
• Spare parts: FGT-P-11872, PWS-320-D208
• Products: Fabrikam FGT-3200, Litware LT-32, LT-32 CCV, Proseware PWG 320
• Procedures: SOP-GBX-010 Gearbox oil change, SOP-LOTO-001 Lockout/tagout of wind turbines, SOP-WAH-003 Working at height and rescue
• Organisations: Fabrikam Getriebetechnik GmbH, Litware Wind Systems, Proseware Lubricants
• Topics: Gearbox lubrication and oil changes, Gearbox temperature, vibration and oil analysis, Safety, isolation and work at height
• Superseded by: SOP-GBX-010 Rev. B - Gearbox oil change

Sources

Footnotes

1. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 2 · ✓ quote verified ↩

2. SOP-GBX-010 - Gearbox oil change, Revision A — table 1, row 2 · table ↩

3. SOP-GBX-010 - Gearbox oil change, Revision A — table 1, row 3 · table ↩

4. SOP-GBX-010 - Gearbox oil change, Revision A — table 1, row 4 · table ↩

5. SOP-GBX-010 - Gearbox oil change, Revision A — table 1, row 7 · table ↩ ↩²

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

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

8. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 8 · paraphrase ↩ ↩²

9. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 13 · ✓ quote verified ↩

10. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 14 · ✓ quote verified ↩

11. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 15 · ✓ quote verified ↩

12. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 16 · ✓ quote verified ↩

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

14. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 19 · ✓ quote verified ↩

15. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 20 · ✓ quote verified ↩

16. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 21 · ✓ quote verified ↩

17. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 22 · ✓ quote verified ↩

18. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 24 · ✓ quote verified ↩

19. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 25 · ✓ quote verified ↩

20. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 26 · ✓ quote verified ↩

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

22. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 28 · ✓ quote verified ↩

23. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 29 · ✓ quote verified ↩

24. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 30 · ✓ quote verified ↩

25. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 31 · ✓ quote verified ↩

26. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 32 · ✓ quote verified ↩

27. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 33 · ✓ quote verified ↩

28. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 34 · ✓ quote verified ↩

29. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 35 · ✓ quote verified ↩

30. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 36 · ✓ quote verified ↩

31. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 38 · ✓ quote verified ↩

32. SOP-GBX-010 - Gearbox oil change, Revision A — table 2, row 2 · table ↩ ↩²

33. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 1 · paraphrase ↩

34. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 2 · paraphrase ↩

35. SOP-GBX-010 - Gearbox oil change, Revision A — table 1, row 5 · table ↩

36. SOP-GBX-010 - Gearbox oil change, Revision A — table 1, row 6 · table ↩

37. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 4 · paraphrase ↩

38. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 6 · paraphrase ↩

39. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 9 · paraphrase ↩

40. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 10 · paraphrase ↩

41. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 11 · paraphrase ↩

42. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 13 · paraphrase ↩

43. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 14 · paraphrase ↩

44. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 15 · paraphrase ↩

45. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 16 · paraphrase ↩

46. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 17 · paraphrase ↩

47. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 19 · paraphrase ↩

48. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 20 · paraphrase ↩

49. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 21 · paraphrase ↩

50. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 22 · paraphrase ↩

51. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 24 · paraphrase ↩

52. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 25 · paraphrase ↩

53. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 26 · paraphrase ↩

54. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 27 · paraphrase ↩

55. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 28 · paraphrase ↩

56. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 29 · paraphrase ↩

57. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 30 · paraphrase ↩

58. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 31 · paraphrase ↩

59. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 32 · paraphrase ↩

60. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 33 · paraphrase ↩

61. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 34 · paraphrase ↩

62. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 35 · paraphrase ↩

63. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 36 · paraphrase ↩

64. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 38 · paraphrase ↩ ↩²

Provenance badges✓ quote verified the quoted words were found verbatim in the source textparaphrase reworded from the source text; numbers checked, no verbatim quotetable values parsed deterministically from the cited table rows