2025-05-02_BTT_V10

Version 10 is valid from 2nd May, 2025 Version 9 is valid until 1st October, 2025

Technical training

Basic Technical Training (BTT)

V10

Publication date: 02052025

Technical Training

Basic Technical Training Standard/ V10 02052025

CONTENTS

1. LIST OF ABBREVIATIONS .................................................................................................................................5

2. TERMS AND DEFINITIONS...............................................................................................................................6

3. CHANGE LOG ................................................................................................................................................... 8

4. SCOPE .............................................................................................................................................................13

5. GENERAL REQUIREMENTS FOR THE BASIC TECHNICAL TRAINING .........................................................13

5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8

Overview

13 14 14 14 15 15 16 16

Target Group

Aims and Objectives

Duration of the Basic Technical Training Standard Modules

Validity Period Course Codes

Participant Prerequisites

Instructor Qualification Prerequisites

6. GENERAL RESOURCES REQUIRED TO DELIVER THE BTT MODULES ........................................................16

6.1 6.2

Practical Training Facilities

16 17

Handouts

7. USING THIS STANDARD TO DEVELOP TRAINING .......................................................................................17

8. ADMINISTRATION AND CERTIFICATION OF MODULES ............................................................................17

8.1

Participant Performance Assessment

9. THE BTT MECHANICAL MODULE .................................................................................................................21

9.1 9.2 9.3 9.4 9.5 9.6

Aims and Objectives for the BTT Mechanical Module

21 21 21 22 22 24

Duration of the BTT Mechanical Module BTT Mechanical Module Participant Ratio Equipment for the BTT Mechanical Module

BTT Mechanical Module Timetable

Detailed Description of the BTT Mechanical Module

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Lesson 7 - Braking Systems ............................................................................................................................... 54 Lesson 8 - Yaw System....................................................................................................................................... 56 Lesson 9 - Cooling System ................................................................................................................................ 58 Lesson 10 - Lubrication System ......................................................................................................................... 60 Lesson 11 - Summary and Theoretical Test ....................................................................................................... 63 Lesson 12 - Training Review .............................................................................................................................. 64

10. THE BTT ELECTRICAL MODULE ....................................................................................................................67

10.1 10.2 10.3 10.4 10.5 10.6

Aims and Objectives of the BTT Electrical Module

67 67 68 68 68 70

Duration of the BTT Electrical Module BTT Electrical Module Participant Ratio Equipment for the BTT Electrical Module

BTT Electrical Module Timetable

Detailed Description of the BTT Electrical Module

Lesson 1 - Introduction ...................................................................................................................................... 70 Lesson 2 - Introduction to Electricity ................................................................................................................. 74 Lesson 3 - Electrical Safety ................................................................................................................................ 77 Lesson 4 - Electrical Components ..................................................................................................................... 83 Lesson 5 - Sensors ............................................................................................................................................. 92 Lesson 6 - Electrical Circuits .............................................................................................................................. 95 Lesson 7 - Electrical Measuring Instruments...................................................................................................... 96 Lesson 8 - Summary and Theoretical Test ......................................................................................................... 98 Lesson 9 - Training Review ................................................................................................................................ 99

11. THE BTT HYDRAULIC MODULE ...................................................................................................................102

11.1 11.2 11.3 11.4 11.5 11.6

Aims and Objectives of the BTT Hydraulic Module

102 102 103 103 103 105

Duration of the BTT Hydraulic Module BTT Hydraulic Module Participant Ratio

Equipment

BTT Hydraulic Module Timetable

Detailed description of the BTT Hydraulic Module

Lesson 1 - Introduction .................................................................................................................................... 105 Lesson 2 - Hydraulic Introduction .................................................................................................................... 110 Lesson 3 - Hydraulic Safety.............................................................................................................................. 111 Lesson 4 - Pumps............................................................................................................................................. 116 Lesson 5 - Actuators ........................................................................................................................................ 118 Lesson 6 - Valves ............................................................................................................................................. 119 Lesson 7 - Accumulators .................................................................................................................................. 125 Lesson 8 - Sensors ........................................................................................................................................... 127 Lesson 9 - Pipes, Hoses and Connections ....................................................................................................... 128 Lesson 10 - Oil and Filters ............................................................................................................................... 130 Lesson 11 - Hydraulic Diagrams ...................................................................................................................... 132

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Lesson 12 - Pressure Measuring Tools............................................................................................................. 134 Lesson 13 - Summary and Theoretical Test ..................................................................................................... 135 Lesson 14 - Training Review ............................................................................................................................ 136

12. THE BTT BOLT TIGHTENING MODULE.......................................................................................................139

12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8

Aims and Objectives of the BTT Bolt Tightening Module

139 139 139 140 140 143 144 146

Duration of the Bolt Tightening Module BTT Bolt Tightening Participant Ratio

Participant Prerequisites for the BTT Bolt Tightening Module

Developing Training Scenarios for this Module

Equipment

BTT Bolt Tightening Module Timetable

Detailed Description of the BTT Bolt Tightening Module

Lesson 1 - Introduction .................................................................................................................................... 146 Lesson 2 - Bolt Tightening in the Wind Industry.............................................................................................. 152 Lesson 3 - Framing the scenario: bolt torquing using powered tools .............................................................158 Lesson 4 - Pre-Task Phase: Planning and Preparation ..................................................................................... 162 Lesson 5 - The Task Phase: Safely and Correctly Torquing Bolts Using Electrical and Hydraulic Tools...........169 Lesson 6 - Post-task Phase: Pack Up and Review ............................................................................................ 175 Lesson 7 - Framing the Scenario: Bolt Tensioning Using Powered Tools........................................................177 Lesson 8 - Pre-Task Phase: Planning and Preparation ..................................................................................... 181 Lesson 9 - The Task Phase: Safe and Correct Tensioning of Bolts Using Hydraulic Tools ...............................186 Lesson 10 - Post-Task Phase: Pack Up and Review.......................................................................................... 191 Lesson 11 - Using Mechanical Handling Aids to Assist with Bolt Tightening Tasks.........................................193 Lesson 12 - Training Review ............................................................................................................................ 198

13. THE BTT INSTALLATION MODULE..............................................................................................................201

13.1 13.2 13.3 13.4 13.5 13.6 13.7

Aims and Objectives of the BTT Installation Module

201 201 202 202 202 202 205

Duration of the BTT Installation Module

BTT Installation Participant Ratio

Participant Prerequisites for the BTT Installation Module

Equipment

BTT Installation Module Timetable

Detailed Description of the BTT Installation Module

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Lesson 9 - Principle of Electrical Completion .................................................................................................. 231 Lesson 10 - Principles of Hydraulic Completion .............................................................................................. 239 Lesson 11 - Principles of Operation with External Generators ........................................................................ 241 Lesson 12 - Introduction to Handover to Commissioning ............................................................................... 246 Lesson 13 - Summary and Theoretical Test ..................................................................................................... 248 Lesson 14 - Training Review ............................................................................................................................ 249

ANNEX 1 - EQUIPMENT LIST ....................................................................................................................................252

ANNEX 2 - SCENARIO DOCUMENTS: BOLT TORQUING .......................................................................................259

ANNEX 3 - SCENARIO DOCUMENTS: BOLT TENSIONING ....................................................................................274

ANNEX 4 - VERSION HISTORY ..................................................................................................................................288

1. LIST OF ABBREVIATIONS

BTT

Basic Technical Training

CO 2

Carbone Dioxide

GWO

Global Wind Organisation

JSA

Job Safety Analysis

LOTO

Lock Out Tag Out

OEM

Original Equipment Manufacturer

PDR

Plan-Do-Review

PPE

Personal Protective Equipment

SWA

Safe Work Approach

TRA

Task Risk Assessment

WTG

Wind Turbine Generator

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2. TERMS AND DEFINITIONS

The purpose of this section is to avoid different interpretations of these terms depending on whoever is reading the standard.

Term

Definition

Bolt Tightening

Refers to the practice of tightening a bolt and includes both torquing and tensioning

Discussion

The purpose of a discussion as a learning activity is to ensure that as many participants as possible reflect on the given topic by taking active part in the discussion. The instructor must arrange the participants in small groups or pairs to ensure that all participants are involved. The instructor can initiate a discussion by asking open-ended questions Critical components used to securely join different parts of the turbine, ensuring structural stability and reliability. Fasteners can include bolts, nuts, washers, and other hardware that hold together parts like the tower segments, nacelle components, rotor blades, and hub Instructor’s feedback should focus on what the participant must adjust to perform correctly. Feedback may involve dialogue, where the participant reflects on his/her understanding or performance Learning activity involving all participants. Group discussions may be conducted in smaller groups. The instructor should step back and only interfere to facilitate the experience exchange between participants. Optimal group size is 4 participants

Fasteners

Feedback

Group discussion

Hand tools Manually operated tools

Handheld tools

Powered and manually operated tools

Hazard

A hazard is any source of potential damage, harm or adverse health effect on something or someone Indication of which tool will provide the safest grip, fit, or attachment to the fastener to be tightened or loosened

Hierarchy of Tooling

HV Bolt

The 'HV' mark comes from the German term 'Hochfest Vorgespannt' meaning high strength preloaded

Installation

Preparation

•

Pre-assembly

•

Assembly

•

Impact Wrench

Also referred to as an impact gun and rattle gun

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For clarity where the word ‘must’ is used in this standard it shall have the same meaning as ‘shall’

Must

Plan-Do- Review

Refers to a job safety and quality management process and may have other names including, but not limited to, Job Safety Analysis, Safe Work Approach, Task Risk Assessment, Task Plan, etc.

Practice

The participants apply what they are learning

A risk is the chance or probability that a person will be harmed or experience an adverse health effect if exposed to a hazard

Risk

A training scenario will reflect a similar work situation. The purpose of scenario based training is to enhance fidelity and by that support learning transfer

Scenario

Verbal form used to indicate requirements strictly to be followed in order to conform to this training standard and from which no deviation is permitted

Shall

Verbal form used to indicate that among several possibilities one is recommended as particularly suitable, without mentioning or excluding others, or that a certain course of action is preferred but not necessarily required

Should

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3. CHANGE LOG

Amendment date

Version

Approved by & date

02052025

GWO TC 10042025

Description of changes

Changes Throughout:

• Aligned standard with GWO Corporate Visual Identity guidelines

Corrected spelling mistakes

•

Section 2. Terms and definitions:

Definition for “fasteners” added

•

Definition for “hand tools” added

•

Definition for “handheld tools” added

•

Definition for “hierarchy of tooling” added

•

Definition for “impact wrench” added

•

Module – BTT Mechanical

Section 9. 1 Aims and objectives for the BTT mechanical module:

• Learning objectives 5 to 12 are moved to their relevant lessons in the module

Section 9.2 Duration of the BTT mechanical module:

• Duration 110 minutes added, total duration now 630 minutes

Lesson 1 Introduction:

Learning objectives renumbered

•

Lesson 3 Mechanical safety:

• Duration 30 minutes added, total duration now 60 minutes

Note is changed

•

New overall learning objective added

•

Element 3.1 Generic safety hazards, risks and potential injuries, and appropriate control measures with handheld tools:

New element added

•

• New learning objectives, note, corresponding learning topics and activities added

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Element 3.2 Why mechanical safety?

Element renumbered

•

• Three new learning objectives and corresponding learning activities added

Element 3.3 Safety signs:

Element renumbered

•

Element 3.4 Types of PPE:

Element renumbered

•

Examples of task-related PPE added

•

Element 3.5 Importance of appropriate isolation:

Element renumbered

•

Element 3.6 Housekeeping:

New element added

•

• New learning objectives, note, corresponding learning topics and activities added

Element 4.1 Principles of bolted connections:

• Three new learning objectives and corresponding learning activities added

Element 4.2 Location of critical bolted and welded connections:

Element title updated

•

Element 4.4 Bolted connections and correct tightening tools:

• New learning objective and corresponding learning activities added

Lesson 5 Use of handheld tools:

Lesson title updated

•

• Two new overall lessons-learning objectives added

Element 5.2 Handheld toll integrity and proper condition:

New element added

•

• Six new learning objectives, note, corresponding learning topics and activities added

Element 5.3 Selecting and using the appropriate tool:

New element added

•

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• Six new learning objectives, note, corresponding learning topics and activities added

Element 5.4 Correctly setting and using a torque wrench:

New element added

•

• Three new learning objectives and corresponding learning activities added

Lesson 6 Gearbox:

• New overall lessons learning objective added

Lesson 7 Braking systems:

• Two new overall lessons learning objectives added

Lesson 8 Yaw system:

• New overall lesson learning objective added

Lesson 9 Cooling system:

• Two new overall lesson learning objectives added

Lesson 10 Lubrication system:

• Two new overall lesson learning objectives added

Module – BTT Electrical

Section 10.2 Duration of the BTT electrical module:

• Duration 10 minutes added, total duration now 605 minutes

Lesson 4 Electrical components:

New overall learning objective added

•

• Duration 10 minutes added, total duration now 110 minutes

Element 4.13 Correct installation and tightening of electrical components:

New element added

•

• New learning objectives, note, corresponding learning topics and activities added

Module – BBT Bolt tightening

Section 11.2 Duration of the BTT bolt tightening module:

• Duration 60 minutes added, total duration now 540 minutes

Lesson 1 Introduction:

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• Duration 15 minutes added, total duration now 45 minutes

Element 1.8 Housekeeping:

New element added

•

• New learning objectives, note, corresponding learning topics and activities added

Lesson 2 Bolt tightening in the wind industry:

• Duration 5 minutes added, total duration now 55 minutes

Element 2.2 Recap of the BTT mechanical:

• New learning objectives, note, corresponding learning topics and activities added

Element 2.3 Bolt tightening theory:

• New learning objectives, note, corresponding learning topics and activities added

Lesson 3 Framing the scenario: bolt torquing using powered tools:

Lesson title updated

•

• Duration 10 minutes added, total duration now 60 minutes

Element 3.1 Introduction to bolt torquing in the wind industry using powered tools and accessories:

Element title updated

•

• Two learning objectives and corresponding learning activities added

Lesson 4 Pre-task phase: Planning and preparation:

• Duration 10 minutes added, total duration now 30 minutes

Element 4.2 Preparing for the task:

• Two new learning objectives and corresponding learning activities added

Element 4.3 Planning for safety:

• Three new learning objectives and corresponding learning activities added

Lesson 5 The task phase:

• Duration 10 minutes added, total duration now 100 minutes

Element 5.1 Setting up equipment:

• New learning objective and corresponding learning activities added

Element 5.2 Bolt torquing:

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• Three new learning objectives and corresponding learning activities added

Element 5.4 Safety, quality and troubleshooting:

• New learning objective and corresponding learning activities added

Lesson 7 Framing the scenario: bolt tensioning using powered tools:

Lesson title updated

•

Lesson 8 Pre-task phase: planning and preparation:

• Duration 10 minutes added, total duration now 30 minutes

Element 8.2 Preparing for the task:

• New learning objective and corresponding learning activities added

Element 8.3 Planning for safety:

• Two new learning objectives and corresponding learning activities added

Element 10.1 Post-use inspection and packing:

New learning activity added to 10.1.7

•

Module – BBT Installation

Section 13.2 Duration of the BTT installation module:

• Duration 5 minutes added, total duration now 1065 minutes

Lesson 5 Handling and storing:

• Duration 5 minutes added, total duration now 75 minutes

Element 5.4 Tools and equipment

• Three new learning objectives and corresponding learning activities added

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4. SCOPE

Global Wind Organisation is a non-profit body founded by the wind turbine manufacturers and owners. Our members strive for an injury free work environment in the wind turbine industry, setting common international standards for safety training and emergency procedures.

This standard describes the requirements for Basic Technical Training modules that are recommended and endorsed by the members of GWO. The Standard comprises of five modules:

Mechanical

Electrical

Hydraulic

Bolt Tightening

Installation

This standard has been developed in response to the demand for recognisable basic technical training in the industry and has been prepared in co-operation between the members of GWO based on risk assessments and factual incident and accident statistics from G+ and the wind industry. GWO members agree that everyone working on one of their sites (wind turbine generators, sub stations, etc.) shall complete Basic Technical Training courses and subsequent company specific training relevant for their assignments. All work should be done in teams of at least two competent persons. Exemptions from the above can be made based on internal company rules.

General feedback on this document can be sent to info@globalwindsafety.org. See globalwindsafety.org on how to raise a complaint about a training provider or report a safety incident occurring during training.

5. GENERAL REQUIREMENTS FOR THE BASIC TECHNICAL TRAINING

Upon completion of the Global Wind Organisation (GWO) Basic Technical Training (BTT), participants will possess an awareness of the hazards encountered when working on hydraulic, mechanical, electrical, and installation systems, and when working with energy powered bolt tightening and how to control and mitigate these hazards, preparing candidates for working both on and offshore in the wind power industry. These training modules can be delivered independently of one another or as stand-alone training. The bolt tightening and installation modules are not part of the mandatory BTT training, and it is up to the duty holder to decide if this should be mandatory training.

5.1 Overview

The GWO Basic Technical Training is divided into the following 5 modules:

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Module 1: Mechanical Module 2: Electrical Module 3: Hydraulic Module 4: Bolt Tightening Module 5: Installation

5.2 Target Group The Basic Technical Training modules are targeted at candidates who have no previous experience of hydraulic, mechanical, electrical or installation systems, or working with energy powered bolt tightening, but may also be used to upskill candidates who have some knowledge but not of its application in wind turbines. 5.3 Aims and Objectives This Basic Technical Training prepares participants for further company specific training by providing them with the necessary training to perform basic hydraulic, mechanical, electrical, bolt tightening and installation tasks.

This course will not make the participant a trained person who is allowed to perform hydraulic, mechanical, electrical, bolt tightening or installation work without supervision.

5.4 Duration of the Basic Technical Training Standard Modules The total contact time for completing the Basic Technical Training Standard is 38 hours and 50 minutes. This is based on the times given in the module timetables and summarised in tables 5.4.1, 5.4.2 and 5.4.3 below.

The training provider must not exceed the time per day given in table 5.4.4 below.

Modules

Duration

Mechanical

10 hours 30 minutes

Electrical

10 hours 5 minutes

Hydraulic

9 hours 15 minutes

Bolt tightening

9 hours 0 minutes

TOTAL 38 hours 50 minutes

Table 5.4.1 - Duration of GWO Mechanical, Electrical, Hydraulic and Bolt Tightening Modules

Modules

Duration

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Mechanical

10 hours 30 minutes

Bolt tightening

9 hours 0 minutes

TOTAL 19 hours 30 minutes

Table 5.4.2 – Duration of GWO Mechanical and Bolt Tightening Modules

Modules

Duration

Mechanical

10 hours 30 minutes

Installation

17 hours 45 minutes

TOTAL 28 hours 15 minutes

Table 5.4.3 – Duration of the GWO Mechanical and Installation Modules

Maximum Duration Per Day

Contact time

8 hours

Total training day

10 hours

Table 5.4.4 - Maximum duration for training days

Contact time includes delivery of course lesson content, practical exercises and activities directly related to these.

Note

The total training day includes contact time, meals and breaks and travel between training sites (where applicable).

If a participant fails to meet the demands of a Basic Technical Training Module, they shall attend a new training in that module.

5.5 Validity Period The Basic Technical Training is an enduring qualification, so a validity period does not apply to this training. A maximum interval between successful completion of the BTT Hydraulic, Mechanical, Electrical, Bolt Tightening and Installation modules does not apply. This is based on the expectation that the participant is actively working in a wind turbine environment. If there is an extended period of absence from applying the skills, retraining and recertification may be required according to national legislation and company policy.

5.6 Course Codes

Module

Course Code

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BTT Mechanical

BTTM

BTT Electrical

BTTE

BTT Hydraulic

BTTH

BTT Bolt Tightening

BTTB

BTT Installation

BTTI

Table 5.6.1 – GWO BTT module course codes

5.7 Participant Prerequisites

All personnel participating must meet the participant prerequisites described in the GWO Requirements for Training.

There are additional prerequisites for both the Bolt Tightening and Installation modules:

a. Before attending the BTT Bolt Tightening Module participants must first complete the BTT Mechanical Module.

b. Before attending the BTT Installation Module participants must first complete both the BTT Mechanical and BTT Bolt Tightening modules.

Furthermore, personnel in the wind power industry must be able to read and write to a sufficient standard to be able to carry out instructions and complete the required documentation. It is an advantage if participants are able to read, speak and write English.

5.8 Instructor Qualification Prerequisites

A competent GWO BTT instructor must adhere to the GWO Requirements for Training.

6. GENERAL RESOURCES REQUIRED TO DELIVER THE BTT MODULES

The training provider shall ensure that staff, facilities, and equipment are in place to support the training of participants.

6.1 Practical Training Facilities

A practical workshop is required that has enough space to accommodate 8 participants, with a respective work area each of approximately 3 square metres.

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6.2 Handouts

Handouts must be given to the participants containing, as a minimum:

Electrical symbols mentioned in the BTT Standard

Hydraulic symbols mentioned in the BTT Standard

Formulas used (Pascal’s Law, Ohm’s Law, Torque)

These handouts could be used as reference for the participants during the entire course and also during the test at the end.

For the Bolt Tightening Module handouts (work instructions, manuals, PDRs and checklists) are found in Annexes 2 and 3. In circumstances where the training is being held on behalf of an OEM or owner operator, equivalent company specific documents may be used instead.

7. USING THIS STANDARD TO DEVELOP TRAINING The training in this standard is designed around the GWO taxonomy described in the GWO Requirements for Training. Theoretical and practical activities must be delivered according to the defined taxonomic level in order to reach the described learning objectives. When teaching about equipment, a generic approach to shall be applied aiming to avoid additional potential product specific formal training after completion of this training. However, national or regional legislation, company gap analysis and location specific risk assessments may require additional product specific familiarisation which is the responsibility of the duty holder.

In addition to this, all training based on this standard including all related resources shall, as a minimum, meet the requirements described in the GWO Requirements for Training.

8. ADMINISTRATION AND CERTIFICATION OF MODULES

8.1 Participant Performance Assessment

The participants will be assessed separately on each module according to the learning objectives, by means of direct observation and supplementary oral questions where appropriate (formative evaluation). Furthermore, the participants will be subjected to a written phase test on the Hydraulic, Mechanical, Electrical and Installation modules according to the learning objectives (summative evaluation). The Bolt Tightening module does not require a written test, assessment of participant performance is conducted during practical exercises.

The written tests can consist of multiple-choice or descriptive answer questions and shall be set at the same taxonomy level as the objective that they are testing.

The multiple-choice test must be conducted in accordance with the following criteria:

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1. There shall be at least one question for each lesson in the module with a minimum of 10 questions for each stand-alone module

There shall be a time limit of 1½ minutes per question

The tests must be individual

The participants shall not communicate with each other during the test

5. The participants shall not communicate with any persons via email, telephone, Skype (or similar) or social media during the test

6. Where a participant does not understand the meaning of a question or a multiple-choice option, the instructor shall be allowed to help the participant to understand the meaning of the question or the multiple-choice options. The instructor shall not give the participant the correct answers to any test questions

Participants may use:

training material

handouts

own notes

participants may not use:

mobile phones (except for calculator)

wearables (e.g. google glasses)

tablets

internet browsers

any other devices similar to those listed above

The multiple-choice test questions cannot be used at any other time during the training in such a way that the participants could recognise that they will be test questions at the end.

At least 70% of the questions in the written test must be answered correctly in order to pass the corresponding module.

In the event that a participant fails the test, the instructor will have a discussion with the participant in order to find out the reason for this. If the reason was due to the misunderstanding of a question or due to language difficulties, the instructor can mark a question as correct, provided that the participant is able to demonstrate the right level of understanding. This must be properly documented by the instructor and kept together with the tests, control measures, evaluations, etc.

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Throughout each of the BTT modules, the instructor will use the participant performance assessment form (see annex 1 of the Requirements for Training) to evaluate the participant’s knowledge and skills, with a high focus on evaluating the participant’s safety awareness.

The instructor shall keep a participant performance assessment form (or adaptation) for each participant until the completion/evaluation of each BTT training module.

The participant performance assessment form (or adaptation) is a final evaluation tool for the instructors to assess participants during practical elements. It allows measurement of the number of violations regarding safety, competency or attitude. The participant performance assessment form shall be used as a progressive evaluation tool to discuss the performance of a participant in guiding them to success. It also serves as supporting documentation if a participant passes or fails the module.

Training providers may adapt the participant performance assessment form to other media.

Training providers must have a documented procedure in place for dealing with participants not meeting the stated learning outcome.

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BTT Mechanical Module

(BTTM)

Global Wind Organisation / www.globalwindsafety.org

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9. THE BTT MECHANICAL MODULE

9.1 Aims and Objectives for the BTT Mechanical Module The aim of this BTT Mechanical Module is to give the participants the knowledge and skills to carry out basic mechanical tasks (supervised by an experienced technician), using safe working procedures and the correct PPE.

After having successfully completed this BTT Mechanical module, the participants can:

1) Describe the main components, mechanical systems and basic operation of wind turbines (Knowledge, basic level)

2) Discuss risks and hazards associated with mechanics (Knowledge, intermediate level)

3) Explain the principles of bolted and welded connections and their inspection (Knowledge, intermediate level)

4) Apply handheld tools correctly and safely (Skills, intermediate level)

9.2 Duration of the BTT Mechanical Module

The total contact time for completing the BTT Mechanical module is 10 hours and 30 minutes.

The training provider must not exceed the time per day given in the table 9.2.1 below.

Maximum Duration Per Day

Contact time

8 hours

Total training day

10 hours

Table 9.2.1 – Maximum duration for training days

Contact time includes delivery of course lesson content, practical exercises and activities directly related to these.

Note

The total training day includes contact time, meals and breaks and travel between training sites (where applicable).

9.3 BTT Mechanical Module Participant Ratio

The ratio shown for theory sessions indicates the maximum number of participants per instructor attending the course.

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Practical ratios indicate the maximum number of participants to be supervised by an instructor during each activity.

Module

Session

Instructor to Participant Ratio

Theory

1:12

BTT Mechanical

Practical

1:8

Table 9.3.1 - Instructor to participant ratio

9.4 Equipment for the BTT Mechanical Module

The equipment required for training as listed in Annex 1 must be available and must fulfil national legal requirements.

9.5 BTT Mechanical Module Timetable

The order in which elements of this Module training are delivered may vary according to the lesson plans prepared for delivering by the training provider.

The delivery of this module must comply with the requirements described in the GWO Requirements for Training .

Lesson

Element

Duration

1. Introduction

1.1

Safety and emergency procedures

1.2

Facilities

1.3

Introduction

1.4

Aims and objectives

1.5

Ongoing assessment

1.6

Motivation

1.7

Human factors TOTAL

30 min.

2. Mechanical introduction

2.1

Main components of the structure

2.2

Main mechanical systems

2.3

How a turbine works TOTAL

60 min.

Generic safety hazards, risks and potential injuries, and appropriate control measures with handheld tools

3. Mechanical safety

3.1

3.2

Why mechanical safety?

3.3

Safety signs

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3.4

Types of PPE

3.5

The importance of appropriate isolation

3.6

Housekeeping TOTAL

60 min.

4. The principles of bolted and welded connections

4.1

The principles of bolted connections

The locations of critical bolted and welded connections

4.2

4.3

Inspection of welded connections

Bolted connections and correct tightening tools TOTAL

4.4

95 min.

5. Use of Handheld Tools

5.1

Metric system

5.2

Handheld tool integrity and proper condition

5.3

Selecting and using the correct tool

5.4

Correctly setting and using a torque wrench

5.5

Feeler gauges

5.6

Vernier Callipers

5.7

Dial gauge TOTAL

135 min.

6. Gearbox

6.1

The function and operating principles

6.2

Inspection of the gearbox TOTAL

30 min.

The function of the mechanical and aerodynamic brake

7. Braking systems

7.1

7.2

Inspection of the mechanical brake system TOTAL

40 min.

8. Yaw system

8.1

The function of the yaw system

8.2

Inspection of the yaw system TOTAL

30 min.

9. Cooling system

9.1

Components requiring cooling and why

9.2

Inspection of the cooling systems TOTAL

30 min.

10. Lubrication system

10.1 Components requiring lubrication and why 10.2 Inspection of the lubrication systems TOTAL

75 min.

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11. Summary and theoretical test

11.1 Summary 11.2 Theoretical test TOTAL 12.1 Training review TOTAL

30 min.

12. Training review

15 min.

GRAND TOTAL

630 min.

Table 9.5.1 – BTT Mechanical module timetable

9.6 Detailed Description of the BTT Mechanical Module LESSON 1 - INTRODUCTION

30 min.

The aim of this lesson is to enable the participants on the GWO BTT Mechanical Module training to engage in the training safely and with motivation, while recognising what is expected of them during the training.

If this module is delivered combined with other BTT modules to the same participants, the redundant introductory elements shall not be repeated

Note

After having successfully completed this lesson, the participants can:

5) Describe the module content and the facilities involved to ensure a clear understanding of what is expected during the module (Knowledge, basic level)

6) Name and point out local emergency procedures and facilities (Knowledge, basic level)

7) Describe the relevant human factors and the implications thereof (Knowledge, basic level)

ELEMENT 1.1 - SAFETY INSTRUCTIONS AND EMERGENCY PROCEDURES

Learning objectives:

8) The participants can recognise the safety instructions, rules and emergency procedures (Knowledge, basic level)

9) The participants can show interest or curiosity in the safety and emergency procedures (Ability, basic level)

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The instructor shall:

Explain and ask open ended questions concerning:

a. safety instructions according to internal procedures

b. emergency procedures and emergency exits in the areas where the participants can be expected to be located during the module

The participants shall:

Engage in answering the above questions

ELEMENT 1.2 - FACILITIES

Learning objective:

10) The participants can recognise the facilities at the training location (Knowledge, basic level)

The instructor shall:

Give a general description of the facilities at the location (administration, dining area, restrooms and toilets, etc.)

The participants shall:

Note relevant facilities and ask questions when in doubt about facilities

ELEMENT 1.3 - INTRODUCTION

Learning objective:

11) The participants can show interest in fellow participants and the programme of the BTT Mechanical Module (Ability, basic level)

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The instructor shall:

Explain and ask open ended questions about the programme of the BTT Mechanical module, including breaks and mealtimes

Give a short introduction about themselves, including their backgrounds as instructors

Ask for participants’ expectations of the training and their learning outcome

The participants shall:

Give a short introduction of themselves, including their job function, and share their expectations of the training and learning outcome expectation for the training

ELEMENT 1.4 - AIMS AND OBJECTIVES

Learning objective:

12) The participants can recognise the scope and main objectives of the BTT Mechanical Module (Knowledge, basic level)

The instructor shall:

Explain the scope and main objectives of the BTT Mechanical Module

Involve participants through questions about the participants’ understanding and individual experiences relevant to the BTT Mechanical Module

The participants shall:

Engage in answering questions, and share experiences relevant to the BTT Mechanical Module

ELEMENT 1.5 - ONGOING ASSESSMENTS

Learning objective:

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