1 Table of contents 269

2024-06-24_BTT_V9

1. List of Abbreviations		5
2. Terms and Definitions		6
3. Change Log		8
4. Scope		10
5. General Requirements for the Basic Technical Training		10
5.1 Overview		10
5.2 Target Group		11
5.3 Aims and Objectives		11
5.4 Duration of the Basic Technical Training Standard Modules		11
5.5 Validity Period		12
5.6 Course Codes		13
5.7 Participant Prerequisites		13
5.8 Instructor Qualification Prerequisites		13
6. General Resources Required to Deliver the BTT Modules		13
6.1 Practical Training Facilities		14
6.2 Handouts		14
7. Using this Standard to Develop Training		14
8. Administration and Certification of Modules		14
8.1 Participant Performance Assessment		14
9. The BTT Mechanical Module		18
9.1 Aims and Objectives for the BTT Mechanical Module		18
9.2 Duration of the BTT Mechanical Module		18
9.3 BTT Mechanical Module Participant Ratio		19
9.4 Equipment for the BTT Mechanical Module		19
9.5 BTT Mechanical Module Timetable		19
9.6 Detailed Description of the BTT Mechanical Module		21
Lesson 1 - Introduction		21
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		22
ELEMENT 1.2 - Facilities		22
ELEMENT 1.3 - Introduction		23
ELEMENT 1.4 - Aims and Objectives		23
ELEMENT 1.5 - Ongoing Assessments		24
ELEMENT 1.6 - Motivation		24
ELEMENT 1.7 - Human factors		25
Lesson 2 - Mechanical Introduction		25
ELEMENT 2.1 - Main Components of the Structure		26
ELEMENT 2.2 - Main Mechanical Systems		27
ELEMENT 2.3 - How a Turbine Works		27
Lesson 3 - Mechanical Safety		28
ELEMENT 3.1 - Why Mechanical Safety		28
ELEMENT 3.2 - Safety Signs		29
ELEMENT 3.3 - Types of PPE		30
ELEMENT 3.4 - The Importance of Appropriate Isolation		30
Lesson 4 - The Principles of Bolted and Welded Connections		31
ELEMENT 4.1 - The principles of bolted connections		31
ELEMENT 4.2 - The Locations of Important Bolted and Welded Connections		32
ELEMENT 4.3 - Inspection of Welded Connections		33
ELEMENT 4.4 - Bolt Connections and Correct Tightening Tools		33
Lesson 5 - Use of Manual Tightening and Measuring Tools		34
ELEMENT 5.1 - Metric System		34
ELEMENT 5.2 - Selecting and Using the Correct Manual Tightening Tools		35
ELEMENT 5.3 - Correctly Setting and Using a Torque Wrench		35
ELEMENT 5.4 - Feeler Gauges		36
ELEMENT 5.5 - Callipers		37
ELEMENT 5.6 - Dial Gauges		37
Lesson 6 - Gearbox		38
ELEMENT 6.1 - Function and Operating Principles		38
ELEMENT 6.2 - Inspection of the Gearbox		39
Lesson 7 - Braking Systems		40
ELEMENT 7.1 - The Function of the Mechanical and the Aerodynamic Brakes		40
ELEMENT 7.2 - Inspection of the Mechanical Brake System		41
Lesson 8 - Yaw System		42
ELEMENT 8.1 - The Function of the Yaw System		42
ELEMENT 8.2 - Inspection of the Yaw System		43
Lesson 9 - Cooling System		43
ELEMENT 9.1 - The function of the Cooling System		43
ELEMENT 9.2 - Inspection of the Cooling System		45
Lesson 10 - Lubrication System		45
ELEMENT 10.1 - Components Requiring Lubrication, and Why		46
ELEMENT 10.2 - Inspection of Lubrication Systems		47
Lesson 11 - Summary and Theoretical Test		48
ELEMENT 11.1 - Summary		48
ELEMENT 11.2 - Theoretical Test		48
Lesson 12 - Training Review		49
ELEMENT 12.1 - Training Review		49
ELEMENT 12.2 - Feedback Session		49
10. The BTT Electrical Module		51
10.1 Aims and Objectives of the BTT Electrical Module		51
10.2 Duration of the BTT Electrical Module		51
10.3 BTT Electrical Module Participant Ratio		52
10.4 Equipment for the BTT Electrical Module		52
10.5 BTT Electrical Module Timetable		52
10.6 Detailed Description of the BTT Electrical Module		54
Lesson 1 - Introduction		54
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		54
ELEMENT 1.2 - Facilities		55
ELEMENT 1.3 - Introduction		55
ELEMENT 1.4 - Aims and Objectives		56
ELEMENT 1.5 - Ongoing Assessments		56
ELEMENT 1.6 - Motivation		57
ELEMENT 1.7 - Human Factors		58
Lesson 2 - Introduction to Electricity		58
ELEMENT 2.1 - Direct Current		59
ELEMENT 2.2 - Ohm’s Law		59
ELEMENT 2.3 - Alternating Current		60
ELEMENT 2.4 - Alternating Current/Direct Current		60
Lesson 3 - Electrical Safety		61
ELEMENT 3.1 - Why Electrical Safety?		61
ELEMENT 3.2 - Low/High Voltage		62
ELEMENT 3.3 - PE and GFCI/RCD		63
ELEMENT 3.4 - Stored Energy		64
ELEMENT 3.5 - Static Electricity		65
ELEMENT 3.6 - Safety Signs		65
ELEMENT 3.7 - Types of PPE		66
ELEMENT 3.8 - The Importance of Appropriate Isolation		66
Lesson 4 - Electrical Components		67
ELEMENT 4.1 - Resistors		67
ELEMENT 4.2 - Batteries		68
ELEMENT 4.3 - Switches		68
ELEMENT 4.4 - Contactors		69
ELEMENT 4.5 - Relays		70
ELEMENT 4.6 - Diodes		70
ELEMENT 4.7 - Bridge Rectifiers		71
ELEMENT 4.8 - Capacitors		71
ELEMENT 4.9 - Transformers		72
ELEMENT 4.10 - Generators and Motors		73
ELEMENT 4.11 - Fuses and Circuit Breakers		73
ELEMENT 4.12 - Processor Control Systems		74
Lesson 5 - Sensors		75
ELEMENT 5.1 - Introduction to Sensors		75
ELEMENT 5.2 - Wind Sensors		75
ELEMENT 5.3 - Temperature Sensors		76
ELEMENT 5.4 - Position Sensors		76
ELEMENT 5.5 - Other Sensors		77
Lesson 6 - Electrical Circuits		77
ELEMENT 6.1 - Symbols and Diagrams		78
ELEMENT 6.2 - Assembly of an Electrical Circuit		78
Lesson 7 - Electrical Measuring Instruments		79
ELEMENT 7.1 - Symbols and Settings on Electrical Measuring Instruments		79
ELEMENT 7.2 - How to Measure with Electrical Measuring Instruments		80
ELEMENT 7.3 - Measuring Points		81
Lesson 8 - Summary and Theoretical Test		81
ELEMENT 8.1 - Summary		81
ELEMENT 8.2 - Theoretical Test		82
Lesson 9 - Training Review		82
ELEMENT 9.1 - Training Review		82
ELEMENT 9.2 - Feedback Session		83
11. The BTT Hydraulic Module		85
11.1 Aims and Objectives of the BTT Hydraulic Module		85
11.2 Duration of the BTT Hydraulic Module		85
11.3 BTT Hydraulic Module Participant Ratio		86
11.4 Equipment		86
11.5 BTT Hydraulic Module Timetable		86
11.6 Detailed description of the BTT Hydraulic Module		88
Lesson 1 - Introduction		88
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		89
ELEMENT 1.2 - Facilities		89
ELEMENT 1.3 - Introduction		90
ELEMENT 1.4 - Aims and Objectives		90
ELEMENT 1.5 - Ongoing Assessments		91
ELEMENT 1.6 - Motivation		91
ELEMENT 1.7 - Human factors		92
Lesson 2 - Hydraulic Introduction		93
ELEMENT 2.1 - The Hydraulic System		93
ELEMENT 2.2 - Pascal’s Law		94
Lesson 3 - Hydraulic Safety		94
ELEMENT 3.1 - Why Hydraulic Safety		94
ELEMENT 3.2 - High Pressure Systems		95
ELEMENT 3.3 - Stored Energy		96
ELEMENT 3.4 - Safety Signs		97
ELEMENT 3.5 - Chemicals		97
ELEMENT 3.6 - Types of PPE		98
ELEMENT 3.7 - Importance of Appropriate Isolation		99
Lesson 4 - Pumps		99
ELEMENT 4.1 - Introduction to Pumps		99
ELEMENT 4.2 - Pumps Exercise		100
Lesson 5 - Actuators		101
ELEMENT 5.1 - Introduction to Actuators		101
Lesson 6 - Valves		102
ELEMENT 6.1 - Introduction to Valves		102
ELEMENT 6.2 - Directional Control Valves		102
ELEMENT 6.3 - Pressure Relief Valves		103
ELEMENT 6.4 - Pressure Reduction Valves		104
ELEMENT 6.5 - Needle Valves		105
ELEMENT 6.6 - Non-return Valves		106
ELEMENT 6.7 - Throttle Valves		106
ELEMENT 6.8 - Restrictor Valves		107
Lesson 7 - Accumulators		108
ELEMENT 7.1 - Introduction to Accumulators		108
ELEMENT 7.2 - Pre-charge Pressure		109
Lesson 8 - Sensors		109
ELEMENT 8.1 - Introduction to Sensors		110
ELEMENT 8.2 - Pressure Sensors		110
Lesson 9 - Pipes, Hoses and Connections		111
ELEMENT 9.1 - Oil Transfer		111
ELEMENT 9.2 - Hydraulic Connections		112
Lesson 10 - Oil and Filters		112
ELEMENT 10.1 - Procedures for Handling of Oil		113
ELEMENT 10.2 - Collecting Oil AND GREASE Sample		113
ELEMENT 10.3 - Checking Oil Levels		114
ELEMENT 10.4 - Filters		114
Lesson 11 - Hydraulic Diagrams		115
ELEMENT 11.1 - Symbols and Diagrams		115
ELEMENT 11.2 - Identifying Measuring Points		116
Lesson 12 - Pressure Measuring Tools		117
ELEMENT 12.1 - Pressure Gauge/Manometer		117
ELEMENT 12.2 - Pressure Measurement		118
Lesson 13 - Summary and Theoretical Test		118
ELEMENT 13.1 - Summary		118
ELEMENT 13.2 - Theoretical Test		119
Lesson 14 - Training Review		119
ELEMENT 14.1 - Training Review		119
ELEMENT 14.2 - Feedback Session		120
12. The BTT Bolt Tightening Module		122
12.1 Aims and Objectives of the BTT Bolt Tightening Module		122
12.2 Duration of the Bolt Tightening Module		122
12.3 BTT Bolt Tightening Participant Ratio		122
12.4 Participant Prerequisites for the BTT Bolt Tightening Module		123
12.5 Developing Training Scenarios for this Module		123
12.6 Equipment		126
12.7 BTT Bolt Tightening Module Timetable		127
12.8 Detailed Description of the BTT Bolt Tightening Module		129
Lesson 1 - Introduction		129
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		129
ELEMENT 1.2 - Facilities		129
ELEMENT 1.3 - Introduction		130
ELEMENT 1.4 - Aims and Objectives		131
ELEMENT 1.5 - Ongoing Assessments		131
ELEMENT 1.6 - Motivation		132
ELEMENT 1.7 - Human Factors		132
Lesson 2 - Bolt Tightening in the Wind Industry		133
ELEMENT 2.1 - Limitations of the Training		134
ELEMENT 2.2 - Recap of the BTT Mechanical		134
ELEMENT 2.3 - Bolt Tightening Theory		136
ELEMENT 2.4 - Quality Assurance in Bolt Tightening		137
Lesson 3 - Framing the Scenario: Bolt Torquing Using Energy Powered Tools		138
ELEMENT 3.1 - Introduction to Bolt Torquing in the Wind Industry Using Energy Powered Tools and Accessories		138
ELEMENT 3.2 - Attitude Requirements for Working with Energy Powered Torquing Tools and Accessories		140
Lesson 4 - Pre-Task Phase: Planning and Preparation		141
ELEMENT 4.1 - Planning the Task		142
ELEMENT 4.2 - Preparing for the Task		144
ELEMENT 4.3 - Planning for Safety		145
Lesson 5 - The Task Phase: Safely and Correctly Torquing Bolts Using Electrical and Hydraulic Tools		147
ELEMENT 5.1 - Setting Up Equipment for Use		147
ELEMENT 5.2 - Bolt Torquing		149
ELEMENT 5.3 - Bolt Loosening		149
ELEMENT 5.4 - Safety, Quality and Trouble Shooting		150
Lesson 6 - Post-task Phase: Pack Up and Review		152
ELEMENT 6.1 - Post-use Inspection and Packing		152
ELEMENT 6.2 - Post-Job Documentation		153
Lesson 7 - Framing the Scenario: Bolt Tensioning Using Energy Powered Tools		154
ELEMENT 7.1 - Introduction to Bolt Tensioning in the Wind Industry Using Energy Powered Tools and Accessories		154
ELEMENT 7.2 - Attitude Requirements for Working with Energy Powered Tensioning Tools and Accessories		156
Lesson 8 - Pre-Task Phase: Planning and Preparation		157
ELEMENT 8.1 - Planning the Task		157
ELEMENT 8.2 - Preparing for the Task		159
ELEMENT 8.3 - Planning for Safety		161
Lesson 9 - The Task Phase: Safe and Correct Tensioning of Bolts Using Hydraulic Tools		162
ELEMENT 9.1 - Setting Up Equipment for Use		163
ELEMENT 9.2 - Bolt Tensioning		164
ELEMENT 9.3 - Bolt Loosening		165
ELEMENT 9.4 - Safety, quality and trouble shooting		166
Lesson 10 - Post-Task Phase: Pack Up and Review		167
ELEMENT 10.1 - Post-use Inspection and Packing		168
ELEMENT 10.2 - Post-job Documentation		168
Lesson 11 - Using Mechanical Handling Aids to Assist with Bolt Tightening Tasks		169
ELEMENT 11.1 - Mechanical Handling Aids Typically Used in the Wind Industry		170
ELEMENT 11.2 - Using Mechanical Handling Aids		171
ELEMENT 11.3 - Hazards Associated with Using Mechanical Handling Aids		172
ELEMENT 11.4 - Mitigating Hazards Associated with Mechanical Handling Aids		173
Lesson 12 - Training Review		174
ELEMENT 12.1 - Training Review		174
ELEMENT 12.2 - Feedback Session		175
13. The BTT Installation Module		177
13.1 Aims and Objectives of the BTT Installation Module		177
13.2 Duration of the BTT Installation Module		177
13.3 BTT Installation Participant Ratio		178
13.4 Participant Prerequisites for the BTT Installation Module		178
13.5 Equipment		178
13.6 BTT Installation Module Timetable		178
13.7 Detailed Description of the BTT Installation Module		181
Lesson 1 - Introduction		181
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		181
ELEMENT 1.2 - Facilities		182
ELEMENT 1.3 - Introduction		182
ELEMENT 1.4 - Aims and objectives		183
ELEMENT 1.5 - Ongoing Assessments		183
ELEMENT 1.6 - Motivation		184
ELEMENT 1.7 - Human Factors		184
Lesson 2 - Introduction to Installation		185
ELEMENT 2.1 - Installation overview		186
ELEMENT 2.2 - Why Installation Safety		186
ELEMENT 2.3 - Safety Signs		188
ELEMENT 2.4 - Types of PPE		189
ELEMENT 2.5 - The Importance of Appropriate Isolation		189
Lesson 3 - General Procedures for Working Onsite with Installation		190
ELEMENT 3.1 - Checklist, Work Instructions, Etc.		190
ELEMENT 3.2 - Housekeeping		191
Lesson 4 - Installation Environments		192
ELEMENT 4.1 - Installation Environments		192
Lesson 5 - Handling and Storing		193
ELEMENT 5.1 - Risks and Hazards Associated with Handling and Storing		193
ELEMENT 5.2 - Reception/Inspection		193
ELEMENT 5.3 - Unloading and Storage of Blades, Nacelle, Tower Sections and Hub		194
ELEMENT 5.4 - Tools and Equipment		195
ELEMENT 5.5 - Returning Goods and Components		196
Lesson 6 - Lifting Operations		197
ELEMENT 6.1 - Types of Lifting		197
ELEMENT 6.2 - Risks and Hazards Associated with Lifting Operations		198
ELEMENT 6.3 - Roles and Responsibilities		200
Lesson 7 - Main Component Preparation, Pre-assembly and Assembly		200
ELEMENT 7.1 - Preparation, Pre-assembly and Assembly		201
ELEMENT 7.2 - Risks and Hazards Associated with Main Component Preparation, Pre-assembly and Assembly		202
ELEMENT 7.3 - Challenges When Assembling Main Components		203
Lesson 8 - Principles of Mechanical Completion		203
ELEMENT 8.1 - Introduction to Mechanical Completion		204
ELEMENT 8.2 - Examples of Mechanical Completion		204
ELEMENT 8.3 - Risks and Hazards Associated with Mechanical Completion		205
Lesson 9 - Principle of Electrical Completion		206
ELEMENT 9.1 - Introduction to Electrical Completion		206
ELEMENT 9.2 - Examples of Electrical Completion		206
ELEMENT 9.3 - Risks and Hazards Associated with Handling and Working with Cables		207
ELEMENT 9.4 - Different Types of Cables		208
ELEMENT 9.5 - Simple Installation Diagrams		209
ELEMENT 9.6 - Cutting and Crimping Cables		209
ELEMENT 9.7 - Marking, Routing and Termination of all Cable Types		211
Lesson 10 - Principles of Hydraulic Completion		213
ELEMENT 10.1 - Introduction to Hydraulic Completion		213
ELEMENT 10.2 - Examples of Hydraulic Completion		213
ELEMENT 10.3 - Risks and Hazards Associated with Hydraulic Completion		214
Lesson 11 - Principles of Operation with External Generators		215
ELEMENT 11.1 - Principles of Yaw, Rotor and Blade Operation without Grid-power		216
ELEMENT 11.2 - Risks and Hazards Associated with the Operation of Auxiliary Systems with External Generators		216
ELEMENT 11.3 - Preconditions for the Operation of Lifts with an External Generator		217
ELEMENT 11.4 - Preconditions for Operation of Internal Cranes with an External Generator		218
ELEMENT 11.5 - Use of External Generators for Other Auxiliary Uses		219
Lesson 12 - Introduction to Handover to Commissioning		220
ELEMENT 12.1 - Handover to Commissioning		220
ELEMENT 12.2 - Risks and Hazards Associated with Handing Over to Commissioning		221
Lesson 13 - Summary and Theoretical Test		221
ELEMENT 13.1 - Summary		222
ELEMENT 13.2 - Theoretical Test		222
Lesson 14 - Training Review		222
ELEMENT 14.1 - Training Review		223
ELEMENT 14.2 - Feedback Session		223
Annex 1 - Equipment list		225
Annex 2 - Scenario documents: Bolt torquing		232
Annex 3 - Scenario documents: Bolt tensioning		247
Annex 4 - Version History		261

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