1 Table of contents 157

2023-05-03_BR_V4

1. LIST OF ABBREVIATIONS		4
2. TERMS AND DEFINITIONS		4
3. CHANGE LOG		5
4. SCOPE		6
5. GENERAL REQUIREMENTS FOR THE GWO BLADE REPAIR		6
5.1 Target Group		6
5.2 Aims and Objectives		6
5.3 Validity Period		7
5.4 Course Codes		7
5.5 Participant Prerequisites for the Blade Repair Module		7
6. GENERAL RESOURCES REQUIRED TO DELIVER BLADE REPAIR MODULE		7
6.1 Instructors		7
6.2 Practical Training Facilities		8
6.3 Training Equipment		8
7. USING THIS STANDARD TO DEVELOP TRAINING		9
8. ADMINISTRATION AND CERTIFICATION OF MODULE		9
8.1 Participant Performance Assessment		9
9. MODULE – BLADE REPAIR		12
9.1 Aims and Objectives of the Blade Repair Module		12
9.2 Duration		12
9.3 Blade Repair Module Participant Ratio		13
9.4 Blade Repair Module Timetable		13
9.5 Detailed Description of the Blade Repair Module		19
Lesson 1 - INTRODUCTION TO THE TRAINING		19
ELEMENT 1.1 - SAFETY INSTRUCTIONS AND EMERGENCY PROCEDURES		19
ELEMENT 1.2 - FACILITIES		20
ELEMENT 1.3 - INTRODUCTION		20
ELEMENT 1.4 - SCOPE AND MAIN LEARNING OBJECTIVES		21
ELEMENT 1.5 - ONGOING ASSESSMENTS (PARTICIPANT ASSESSMENT FORM)		21
ELEMENT 1.6 - MOTIVATION		21
ELEMENT 1.7 - HUMAN FACTORS		22
Lesson 2 - SAFETY DATA SHEETS		23
ELEMENT 2.1 - SAFETY DATA SHEETS		24
ELEMENT 2.2 - SAFETY DATA SHEET LOCATION		24
ELEMENT 2.3 - SAFETY INSTRUCTIONS		25
ELEMENT 2.4 - HAZARD LABELS AND SYMBOLS		26
ELEMENT 2.5 - PERSONAL PROTECTIVE EQUIPMENT		26
Lesson 3 - WORK INSTRUCTION		27
ELEMENT 3.1 - WORK INSTRUCTION (WI)		27
ELEMENT 3.2 - LOCATE WORK INSTRUCTION		28
Lesson 4 - RISK ASSESSMENT		28
ELEMENT 4.1 - RISK ASSESSMENTS		29
ELEMENT 4.2 - UPDATED RISK ASSESSMENT		29
Lesson 5 - SECURE AN AREA		30
ELEMENT 5.1 - LOCATE PROCEDURES		30
ELEMENT 5.2 - SECURING THE AREA		30
Lesson 6 - CONTAMINATION		31
ELEMENT 6.1 - CHARACTERISTICS		31
ELEMENT 6.2 - WORK INSTRUCTIONS AS MITIGATION		32
ELEMENT 6.3 - AVOIDING CONTAMINATION		33
Lesson 7 - WASTE SEGREGATION		34
ELEMENT 7.1 - WHY SEGREGATE WASTE?		34
ELEMENT 7.2 - CORRECT WASTE SEGREGATION		34
ELEMENT 7.3 - WASTE SEGREGATION INFORMATION		35
Lesson 8 - ERGONOMICS		35
ELEMENT 8.1 - CLASSROOM		36
ELEMENT 8.2 - WORKSHOP		36
ELEMENT 8.3 - BLADEWORK		36
Lesson 9 - LOCK OUT TAG OUT (LOTO)		37
ELEMENT 9.1 - LOCK OUT TAG OUT		38
Lesson 10 - PERSONAL PROTECTIVE EQUIPMENT		38
ELEMENT 10.1 - PURPOSE		39
ELEMENT 10.2 - APPLICATION		39
ELEMENT 10.3 - LIMITATIONS		40
ELEMENT 10.4 - TASK SPECIFIC		40
ELEMENT 10.5 - DISPOSAL		41
Lesson 11 - MASKS AND FILTERS		42
ELEMENT 11.1 - PURPOSE		42
ELEMENT 11.2 - FILTER CATEGORIES		42
ELEMENT 11.3 - CATEGORIES AND LIFETIME		43
ELEMENT 11.4 - MASKS		44
ELEMENT 11.5 - APPLY FILTERS		44
Lesson 12 - CHEMICAL SAFETY		45
ELEMENT 12.1 - PURPOSE		45
ELEMENT 12.2 - TRANSFER PROCEDURES		46
ELEMENT 12.3 - INFORMATION ABOUT CHEMICALS		47
ELEMENT 12.4 - EQUIPMENT CHECK		47
ELEMENT 12.5 - PREVENTION AND MITIGATION		48
Lesson 13 - COMPOSITES AND BLADE CONSTRUCTION		49
ELEMENT 13.1 - AERODYNAMICS		49
ELEMENT 13.2 - BLADE CONSTRUCTION		50
ELEMENT 13.3 - SANDWICH PANEL		52
ELEMENT 13.4 - BLADE ENHANCEMENTS		52
ELEMENT 13.5 - FAULTS, IMPLICATIONS AND MITIGATIONS		53
Lesson 14 - MATERIALS		54
ELEMENT 14.1 - REINFORCEMENT MATERIALS		55
ELEMENT 14.2 - MATRIX MATERIALS		55
ELEMENT 14.3 - ADHESIVES		56
ELEMENT 14.4 - SURFACE COATINGS		57
ELEMENT 14.5 - CHEMICAL HANDLING AND APPLICATION		58
ELEMENT 14.6 - CURING		59
Lesson 15 - TOOLS AND EQUIPMENT		60
ELEMENT 15.1 - MECHANICAL, ELECTRICAL AND PNEUMATIC PRINCIPLES		60
ELEMENT 15.2 - UTILISATION OF TOOLS AND MATERIALS		61
ELEMENT 15.3 - CALIBRATION		62
ELEMENT 15.4 - LAMINATION TOOLS		63
ELEMENT 15.5 - HEATING BLANKETS		63
ELEMENT 15.6 - CHECKING ELECTRICAL TOOLS AND EQUIPMENT		64
ELEMENT 15.7 - VIBRATING TOOLS		65
ELEMENT 15.8 - ELECTRICAL SAFETY DEVICES		66
ELEMENT 15.9 - DOCUMENTATION TYPES		67
Lesson 16 - PHASE TEST		68
ELEMENT 16.2 - PHASE TEST		68
Lesson 17 - LAMINATION SKILLS		68
ELEMENT 17.1 - FIBRE ORIENTATION		69
ELEMENT 17.2 - KINKED OR BENT FIBRES		69
ELEMENT 17.3 - OVERLAPS		70
ELEMENT 17.4 - DRY FIBRES AND AIR VOIDS		71
ELEMENT 17.5 - MIXING RATIO		72
ELEMENT 17.6 - CALCULATION OF MATRIX MATERIAL		73
ELEMENT 17.7 - CURING AT ELEVATED TEMPERATURES		74
ELEMENT 17.8 - ASCERTAINING CORRECT CURING		75
ELEMENT 17.9 - AMBIENT TEMPERATURE AND HUMIDITY		76
ELEMENT 17.10 - RECORDING AMBIENT TEMPERATURE AND HUMIDITY		76
Lesson 18 - BASIC LAMINATION		77
ELEMENT 18.1 - MINIMISE RISKS ASSOCIATED WITH COMPOSITE FIBRE WORK		78
ELEMENT 18.2 - FIBREGLASS MATS		78
ELEMENT 18.3 - FIBRE ORIENTATION AND MOULDING THEORY		79
Lesson 19 - SANDWICH PANEL		81
ELEMENT 19.1 - MINIMISE RISKS ASSOCIATED WITH COMPOSITE FIBRE WORK		82
ELEMENT 19.2 - SANDWICH CONSTRUCTION		82
ELEMENT 19.3 - CURING OF FIBRE REINFORCED COMPOSITE LAMINATE		83
ELEMENT 19.4 - PRODUCING A COMPOSITE SANDWICH PANEL		85
ELEMENT 19.5 - TRAILING EDGE SECTION		87
Lesson 20 - PAINTING		88
ELEMENT 20.1 - COMPLETION OF BLADE		88
Lesson 21 - BLADE INSPECTION		90
ELEMENT 21.1 - TYPICAL FAILURES		90
ELEMENT 21.2 - REACTIONS TO DAMAGE CATEGORIES		91
ELEMENT 21.3 - FOCUSED AND SCALED PHOTOGRAPHS		92
ELEMENT 21.4 - TAP TEST		93
ELEMENT 21.5 - LIGHTING		93
ELEMENT 21.6 - INSPECTION TOOLS AND METHODS		94
ELEMENT 21.7 - TYPES OF DAMAGE		95
Lesson 22 - INSPECTION LIGHTNING PROTECTION SYSTEM		96
ELEMENT 22.1 - SURFACE COMPONENTS		96
ELEMENT 22.2 - VISUAL AND CONDUCTIVITY INSPECTION		97
ELEMENT 22.3 - MEASURE RESISTANCE		98
Lesson 23 - SANDING SKILLS		99
ELEMENT 23.1 - SANDING		99
Lesson 24 - GRINDING SKILLS		100
ELEMENT 24.1 - GRINDING		101
Lesson 25 - SURFACE REPAIRS		102
ELEMENT 25.1 - MINIMISE RISKS ASSOCIATED WITH COMPOSITE FIBRE WORK		102
ELEMENT 25.2 - FILLER ADHESION		103
ELEMENT 25.3 - REPRODUCE SURFACE PROFILE		104
ELEMENT 25.4 - PAINT ADHESION		104
ELEMENT 25.5 - LAYER THICKNESS		105
ELEMENT 25.6 - APPLY PAINT WITH A ROLLER		105
ELEMENT 25.7 - LAYER THICKNESS WITH WET FILM		106
ELEMENT 25.8 - RECORD AMBIENT TEMPERATURE AND HUMIDITY		106
ELEMENT 25.9 - INSPECTION AND DOCUMENTATION		107
Lesson 26 - LAMINATE REPAIRS		108
ELEMENT 26.1 - MINIMISE RISKS ASSOCIATED WITH COMPOSITE FIBRE WORK		108
ELEMENT 26.2 - SAFE REMOVAL OF DAMAGED MATERIAL		108
ELEMENT 26.3 - IDENTIFYING FIBRE DIRECTION		110
ELEMENT 26.4 - REINFORCEMENT OVERLAPS AND MATRIX ADHESION		110
ELEMENT 26.5 - MIXING		112
ELEMENT 26.6 - REPAIR LAYERS		112
ELEMENT 26.7 - WETTING OUT FIBRES USING APPROPRIATE TOOLS		113
ELEMENT 26.8 - WETTING OUT FIBRES WITH MATRIX MATERIAL		114
ELEMENT 26.9 - VACUUM CONSOLIDATION		114
ELEMENT 26.10 - CURING THE REPAIR USING HEATING BLANKETS		115
ELEMENT 26.11 - VERIFYING THE CURING		116
ELEMENT 26.12 - RECORDING THE AMBIENT TEMPERATURE AND HUMIDITY		117
Lesson 27 - FILLING AND SHAPING		118
ELEMENT 27.1 - FILLER		118
Lesson 28 - TRAILING EDGE REPAIRS		119
ELEMENT 28.1 - MINIMISE RISKS ASSOCIATED WITH COMPOSITE FIBRE WORK		119
ELEMENT 28.2 - REPAIR TASK		120
ELEMENT 28.3 - CRACK REPAIRS		120
ELEMENT 28.4 - RECREATING BLADE PROFILE		121
ELEMENT 28.5 - RECORD AMBIENT TEMPERATURE AND HUMIDITY		122
Lesson 29 - LEADING EDGE REPAIRS		123
ELEMENT 29.1 - MINIMISE RISKS ASSOCIATED WITH COMPOSITE FIBRE WORK		123
ELEMENT 29.2 - REPAIR TASK		123
ELEMENT 29.3 - LEADING EDGE REPAIR		124
ELEMENT 29.4 - RELOCATE LEADING EDGE		125
Lesson 30 - SANDWICH PANEL REPAIR		126
ELEMENT 30.1 - MINIMISE RISKS ASSOCIATED WITH COMPOSITE FIBRE WORK		126
ELEMENT 30.2 - REPAIR TASK		127
ELEMENT 30.3 - REPAIR INNER AND OUTER LAMINATE		127
ELEMENT 30.4 - REPLACEMENT CORE		128
ELEMENT 30.5 - INSPECTION AND DOCUMENTATION		129
Lesson 31 - BOND LINE REPAIRS		130
ELEMENT 31.1 - DEBONDING		130
ELEMENT 31.2 - INJECTION OF ADHESIVE		131
ELEMENT 31.3 - INJECTING MATERIAL IN THE TRAILING EDGE		132
Lesson 32 - SUMMARY AND FINAL TEST		133
ELEMENT 32.2 - SUMMARY		133
ELEMENT 32.3 - FINAL TEST		133
Lesson 33 - TRAINING REVIEW		134
ELEMENT 33.1 - TRAINING REVIEW		134
ELEMENT 33.2 - FEEDBACK SESSION		134
Annex 1 - EQUIPMENT LIST		136
Annex 2 - PRACTICAL EXERCISE (EXAMPLE)		140
Annex 3 - WORK INSTRUCTION (EXAMPLE)		144
Annex 4 - PHOTOCARD		152
Annex 5 - VERSION HISTORY		153

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