1 Table of contents 298

2025-05-02_BTT_V10

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

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 Overview		13
5.2 Target Group		14
5.3 Aims and Objectives		14
5.4 Duration of the Basic Technical Training Standard Modules		14
5.5 Validity Period		15
5.6 Course Codes		15
5.7 Participant Prerequisites		16
5.8 Instructor Qualification Prerequisites		16
6. General Resources Required to Deliver the BTT Modules		16
6.1 Practical Training Facilities		16
9. The BTT Mechanical Module		21
9.1 Aims and Objectives for the BTT Mechanical Module		21
9.2 Duration of the BTT Mechanical Module		21
9.3 BTT Mechanical Module Participant Ratio		21
9.4 Equipment for the BTT Mechanical Module		22
9.5 BTT Mechanical Module Timetable		22
9.6 Detailed Description of the BTT Mechanical Module		24
Lesson 1 - Introduction		24
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		24
ELEMENT 1.2 - Facilities		25
ELEMENT 1.3 - Introduction		25
ELEMENT 1.4 - Aims and Objectives		26
ELEMENT 1.5 - Ongoing Assessments		26
ELEMENT 1.6 - Motivation		27
ELEMENT 1.7 - Human factors		28
Lesson 2 - Mechanical Introduction		28
ELEMENT 2.1 - Main Components of the Structure		29
ELEMENT 2.2 - Main Mechanical Systems		30
ELEMENT 2.3 - How a Turbine Works		30
Lesson 3 - Mechanical Safety		31
ELEMENT 3.1 - Generic safety hazards, risks and potential injuries, and appropriate control measures with handheld tools		32
ELEMENT 3.2 - Why Mechanical Safety		34
ELEMENT 3.3 - Safety Signs		36
ELEMENT 3.4 - Types of PPE		37
ELEMENT 3.5 - The Importance of Appropriate Isolation		37
ELEMENT 3.6 - Housekeeping		38
Lesson 4 - The Principles of Bolted and Welded Connections		40
ELEMENT 4.1 - The principles of bolted connections		40
ELEMENT 4.2 - The Locations of CRITICAL Bolted and Welded Connections		42
ELEMENT 4.3 - Inspection of Welded Connections		43
ELEMENT 4.4 - Bolted Connections and Correct Tightening Tools		43
Lesson 5 - Use of handheld Tools		44
ELEMENT 5.1 - Metric System		44
ELEMENT 5.2 - Handheld tool integrity and proper condition		45
ELEMENT 5.3 - Selecting and using the appropriate tool		47
ELEMENT 5.4 - Correctly Setting and Using a Torque Wrench		49
ELEMENT 5.5 - Feeler Gauges		50
ELEMENT 5.6 - vernier Callipers		51
ELEMENT 5.7 - Dial Gauges		52
Lesson 6 - Gearbox		52
ELEMENT 6.1 - Function and Operating Principles		53
ELEMENT 6.2 - Inspection of the Gearbox		54
Lesson 7 - Braking Systems		54
ELEMENT 7.1 - The Function of the Mechanical and the Aerodynamic Brakes		55
ELEMENT 7.2 - Inspection of the Mechanical Brake System		56
Lesson 8 - Yaw System		56
ELEMENT 8.1 - The Function of the Yaw System		56
ELEMENT 8.2 - Inspection of the Yaw System		57
Lesson 9 - Cooling System		58
ELEMENT 9.1 - The function of the Cooling System		58
ELEMENT 9.2 - Inspection of the Cooling System		60
Lesson 10 - Lubrication System		60
ELEMENT 10.1 - Components Requiring Lubrication, and Why		61
ELEMENT 10.2 - Inspection of Lubrication Systems		62
Lesson 11 - Summary and Theoretical Test		63
ELEMENT 11.1 - Summary		63
ELEMENT 11.2 - Theoretical Test		63
Lesson 12 - Training Review		64
ELEMENT 12.1 - Training Review		64
ELEMENT 12.2 - Feedback Session		64
10. The BTT Electrical Module		67
10.1 Aims and Objectives of the BTT Electrical Module		67
10.2 Duration of the BTT Electrical Module		67
10.3 BTT Electrical Module Participant Ratio		68
10.4 Equipment for the BTT Electrical Module		68
10.5 BTT Electrical Module Timetable		68
10.6 Detailed Description of the BTT Electrical Module		70
Lesson 1 - Introduction		70
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		70
ELEMENT 1.2 - Facilities		71
ELEMENT 1.3 - Introduction		71
ELEMENT 1.4 - Aims and Objectives		72
ELEMENT 1.5 - Ongoing Assessments		73
ELEMENT 1.6 - Motivation		73
ELEMENT 1.7 - Human Factors		74
Lesson 2 - Introduction to Electricity		74
ELEMENT 2.1 - Direct Current		75
ELEMENT 2.2 - Ohm’s Law		75
ELEMENT 2.3 - Alternating Current		76
ELEMENT 2.4 - Alternating Current/Direct Current		76
Lesson 3 - Electrical Safety		77
ELEMENT 3.1 - Why Electrical Safety?		77
ELEMENT 3.2 - Low/High Voltage		78
ELEMENT 3.3 - PE and GFCI/RCD		79
ELEMENT 3.4 - Stored Energy		80
ELEMENT 3.5 - Static Electricity		81
ELEMENT 3.6 - Safety Signs		81
ELEMENT 3.7 - Types of PPE		82
ELEMENT 3.8 - The Importance of Appropriate Isolation		82
Lesson 4 - Electrical Components		83
ELEMENT 4.1 - Resistors		84
ELEMENT 4.2 - Batteries		84
ELEMENT 4.3 - Switches		85
ELEMENT 4.4 - Contactors		85
ELEMENT 4.5 - Relays		86
ELEMENT 4.6 - Diodes		87
ELEMENT 4.7 - Bridge Rectifiers		87
ELEMENT 4.8 - Capacitors		88
ELEMENT 4.9 - Transformers		89
ELEMENT 4.10 - Generators and Motors		89
ELEMENT 4.11 - Fuses and Circuit Breakers		90
ELEMENT 4.12 - Processor Control Systems		91
ELEMENT 4.13 - Correct installation and tightening of electrical components		91
Lesson 5 - Sensors		92
ELEMENT 5.1 - Introduction to Sensors		92
ELEMENT 5.2 - Wind Sensors		92
ELEMENT 5.3 - Temperature Sensors		93
ELEMENT 5.4 - Position Sensors		94
ELEMENT 5.5 - Other Sensors		94
Lesson 6 - Electrical Circuits		95
ELEMENT 6.1 - Symbols and Diagrams		95
ELEMENT 6.2 - Assembly of an Electrical Circuit		96
Lesson 7 - Electrical Measuring Instruments		96
ELEMENT 7.1 - Symbols and Settings on Electrical Measuring Instruments		96
ELEMENT 7.2 - How to Measure with Electrical Measuring Instruments		97
ELEMENT 7.3 - Measuring Points		98
Lesson 8 - Summary and Theoretical Test		98
ELEMENT 8.1 - Summary		99
ELEMENT 8.2 - Theoretical Test		99
Lesson 9 - Training Review		99
ELEMENT 9.1 - Training Review		100
ELEMENT 9.2 - Feedback Session		100
11. The BTT Hydraulic Module		102
11.1 Aims and Objectives of the BTT Hydraulic Module		102
11.2 Duration of the BTT Hydraulic Module		102
11.3 BTT Hydraulic Module Participant Ratio		103
11.4 Equipment		103
11.5 BTT Hydraulic Module Timetable		103
11.6 Detailed description of the BTT Hydraulic Module		105
Lesson 1 - Introduction		105
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		106
ELEMENT 1.2 - Facilities		106
ELEMENT 1.3 - Introduction		107
ELEMENT 1.4 - Aims and Objectives		107
ELEMENT 1.5 - Ongoing Assessments		108
ELEMENT 1.6 - Motivation		108
ELEMENT 1.7 - Human factors		109
Lesson 2 - Hydraulic Introduction		110
ELEMENT 2.1 - The Hydraulic System		110
ELEMENT 2.2 - Pascal’s Law		111
Lesson 3 - Hydraulic Safety		111
ELEMENT 3.1 - Why Hydraulic Safety		111
ELEMENT 3.2 - High Pressure Systems		112
ELEMENT 3.3 - Stored Energy		113
ELEMENT 3.4 - Safety Signs		114
ELEMENT 3.5 - Chemicals		114
ELEMENT 3.6 - Types of PPE		115
ELEMENT 3.7 - Importance of Appropriate Isolation		116
Lesson 4 - Pumps		116
ELEMENT 4.1 - Introduction to Pumps		116
ELEMENT 4.2 - Pumps Exercise		117
Lesson 5 - Actuators		118
ELEMENT 5.1 - Introduction to Actuators		118
Lesson 6 - Valves		119
ELEMENT 6.1 - Introduction to Valves		119
ELEMENT 6.2 - Directional Control Valves		119
ELEMENT 6.3 - Pressure Relief Valves		120
ELEMENT 6.4 - Pressure Reduction Valves		121
ELEMENT 6.5 - Needle Valves		122
ELEMENT 6.6 - Non-return Valves		123
ELEMENT 6.7 - Throttle Valves		124
ELEMENT 6.8 - Restrictor Valves		124
Lesson 7 - Accumulators		125
ELEMENT 7.1 - Introduction to Accumulators		125
ELEMENT 7.2 - Pre-charge Pressure		126
Lesson 8 - Sensors		127
ELEMENT 8.1 - Introduction to Sensors		127
ELEMENT 8.2 - Pressure Sensors		127
Lesson 9 - Pipes, Hoses and Connections		128
ELEMENT 9.1 - Oil Transfer		128
ELEMENT 9.2 - Hydraulic Connections		129
Lesson 10 - Oil and Filters		130
ELEMENT 10.1 - Procedures for Handling of Oil		130
ELEMENT 10.2 - Collecting Oil AND GREASE Sample		130
ELEMENT 10.3 - Checking Oil Levels		131
ELEMENT 10.4 - Filters		132
Lesson 11 - Hydraulic Diagrams		132
ELEMENT 11.1 - Symbols and Diagrams		133
ELEMENT 11.2 - Identifying Measuring Points		133
Lesson 12 - Pressure Measuring Tools		134
ELEMENT 12.1 - Pressure Gauge/Manometer		134
ELEMENT 12.2 - Pressure Measurement		135
Lesson 13 - Summary and Theoretical Test		135
ELEMENT 13.1 - Summary		135
ELEMENT 13.2 - Theoretical Test		136
Lesson 14 - Training Review		136
ELEMENT 14.1 - Training Review		136
ELEMENT 14.2 - Feedback Session		137
12. The BTT Bolt Tightening Module		139
12.1 Aims and Objectives of the BTT Bolt Tightening Module		139
12.2 Duration of the Bolt Tightening Module		139
12.3 BTT Bolt Tightening Participant Ratio		139
12.4 Participant Prerequisites for the BTT Bolt Tightening Module		140
12.5 Developing Training Scenarios for this Module		140
12.6 Equipment		143
12.7 BTT Bolt Tightening Module Timetable		144
12.8 Detailed Description of the BTT Bolt Tightening Module		146
Lesson 1 - Introduction		146
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		146
ELEMENT 1.2 - Facilities		147
ELEMENT 1.3 - Introduction		147
ELEMENT 1.4 - Aims and Objectives		148
ELEMENT 1.5 - Ongoing Assessments		148
ELEMENT 1.6 - Motivation		149
ELEMENT 1.7 - Human Factors		150
ELEMENT 1.8 - Housekeeping		150
Lesson 2 - Bolt Tightening in the Wind Industry		152
ELEMENT 2.1 - Limitations of the Training		153
ELEMENT 2.2 - Recap of the BTT Mechanical		153
ELEMENT 2.3 - Bolt Tightening Theory		155
ELEMENT 2.4 - Quality Assurance in Bolt Tightening		157
Lesson 3 - Framing the scenario: bolt torquing using powered tools		158
ELEMENT 3.1 - Introduction to bolt torquing in the wind industry using powered tools and accessories		159
ELEMENT 3.2 - Attitude Requirements for Working with Powered Torquing Tools and Accessories		162
Lesson 4 - Pre-Task Phase: Planning and Preparation		162
ELEMENT 4.1 - Planning the Task		163
ELEMENT 4.2 - Preparing for the Task		165
ELEMENT 4.3 - Planning for Safety		167
Lesson 5 - The Task Phase: Safely and Correctly Torquing Bolts Using Electrical and Hydraulic Tools		169
ELEMENT 5.1 - Setting Up Equipment for Use		170
ELEMENT 5.2 - Bolt Torquing		171
ELEMENT 5.3 - Bolt Loosening		173
ELEMENT 5.4 - Safety, Quality and Trouble Shooting		174
Lesson 6 - Post-task Phase: Pack Up and Review		175
ELEMENT 6.1 - Post-use Inspection and Packing		176
ELEMENT 6.2 - Post-Job Documentation		176
Lesson 7 - Framing the Scenario: Bolt Tensioning Using Powered Tools		177
ELEMENT 7.1 - Introduction to Bolt Tensioning in the Wind Industry Using Powered Tools and Accessories		178
ELEMENT 7.2 - Attitude Requirements for Working with Energy Powered Tensioning Tools and Accessories		180
Lesson 8 - Pre-Task Phase: Planning and Preparation		181
ELEMENT 8.1 - Planning the Task		181
ELEMENT 8.2 - Preparing for the Task		183
ELEMENT 8.3 - Planning for Safety		185
Lesson 9 - The Task Phase: Safe and Correct Tensioning of Bolts Using Hydraulic Tools		186
ELEMENT 9.1 - Setting Up Equipment for Use		187
ELEMENT 9.2 - Bolt Tensioning		188
ELEMENT 9.3 - Bolt Loosening		189
ELEMENT 9.4 - Safety, quality and trouble shooting		190
Lesson 10 - Post-Task Phase: Pack Up and Review		191
ELEMENT 10.1 - Post-use Inspection and Packing		192
ELEMENT 10.2 - Post-job Documentation		192
Lesson 11 - Using Mechanical Handling Aids to Assist with Bolt Tightening Tasks		193
ELEMENT 11.1 - Mechanical Handling Aids Typically Used in the Wind Industry		194
ELEMENT 11.2 - Using Mechanical Handling Aids		195
ELEMENT 11.3 - Hazards Associated with Using Mechanical Handling Aids		196
ELEMENT 11.4 - Mitigating Hazards Associated with Mechanical Handling Aids		197
Lesson 12 - Training Review		198
ELEMENT 12.1 - Training Review		198
ELEMENT 12.2 - Feedback Session		199
13. The BTT Installation Module		201
13.1 Aims and Objectives of the BTT Installation Module		201
13.2 Duration of the BTT Installation Module		201
13.3 BTT Installation Participant Ratio		202
13.4 Participant Prerequisites for the BTT Installation Module		202
13.5 Equipment		202
13.6 BTT Installation Module Timetable		202
13.7 Detailed Description of the BTT Installation Module		205
Lesson 1 - Introduction		205
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		206
ELEMENT 1.2 - Facilities		206
ELEMENT 1.3 - Introduction		207
ELEMENT 1.4 - Aims and objectives		207
ELEMENT 1.5 - Ongoing Assessments		208
ELEMENT 1.6 - Motivation		208
ELEMENT 1.7 - Human Factors		209
Lesson 2 - Introduction to Installation		209
ELEMENT 2.1 - Installation overview		210
ELEMENT 2.2 - Why Installation Safety		211
ELEMENT 2.3 - Safety Signs		212
ELEMENT 2.4 - Types of PPE		213
ELEMENT 2.5 - The Importance of Appropriate Isolation		213
Lesson 3 - General Procedures for Working Onsite with Installation		214
ELEMENT 3.1 - Checklist, Work Instructions, Etc.		214
ELEMENT 3.2 - Housekeeping		215
Lesson 4 - Installation Environments		216
ELEMENT 4.1 - Installation Environments		216
Lesson 5 - Handling and Storing		217
ELEMENT 5.1 - Risks and Hazards Associated with Handling and Storing		217
ELEMENT 5.2 - Reception/Inspection		218
ELEMENT 5.3 - Unloading and Storage of Blades, Nacelle, Tower Sections and Hub		219
ELEMENT 5.4 - Tools and Equipment		220
ELEMENT 5.5 - Returning Goods and Components		222
Lesson 6 - Lifting Operations		223
ELEMENT 6.1 - Types of Lifting		223
ELEMENT 6.2 - Risks and Hazards Associated with Lifting Operations		224
ELEMENT 6.3 - Roles and Responsibilities		225
Lesson 7 - Main Component Preparation, Pre-assembly and Assembly		226
ELEMENT 7.1 - Preparation, Pre-assembly and Assembly		226
ELEMENT 7.2 - Risks and Hazards Associated with Main Component Preparation, Pre-assembly and Assembly		227
ELEMENT 7.3 - Challenges When Assembling Main Components		228
Lesson 8 - Principles of Mechanical Completion		229
ELEMENT 8.1 - Introduction to Mechanical Completion		229
ELEMENT 8.2 - Examples of Mechanical Completion		230
ELEMENT 8.3 - Risks and Hazards Associated with Mechanical Completion		230
Lesson 9 - Principle of Electrical Completion		231
ELEMENT 9.1 - Introduction to Electrical Completion		231
ELEMENT 9.2 - Examples of Electrical Completion		232
ELEMENT 9.3 - Risks and Hazards Associated with Handling and Working with Cables		233
ELEMENT 9.4 - Different Types of Cables		234
ELEMENT 9.5 - Simple Installation Diagrams		234
ELEMENT 9.6 - Cutting and Crimping Cables		235
ELEMENT 9.7 - Marking, Routing and Termination of all Cable Types		236
Lesson 10 - Principles of Hydraulic Completion		239
ELEMENT 10.1 - Introduction to Hydraulic Completion		239
ELEMENT 10.2 - Examples of Hydraulic Completion		239
ELEMENT 10.3 - Risks and Hazards Associated with Hydraulic Completion		240
Lesson 11 - Principles of Operation with External Generators		241
ELEMENT 11.1 - Principles of Yaw, Rotor and Blade Operation without Grid-power		242
ELEMENT 11.2 - Risks and Hazards Associated with the Operation of Auxiliary Systems with External Generators		242
ELEMENT 11.3 - Preconditions for the Operation of Lifts with an External Generator		243
ELEMENT 11.4 - Preconditions for Operation of Internal Cranes with an External Generator		244
ELEMENT 11.5 - Use of External Generators for Other Auxiliary Uses		245
Lesson 12 - Introduction to Handover to Commissioning		246
ELEMENT 12.1 - Handover to Commissioning		247
ELEMENT 12.2 - Risks and Hazards Associated with Handing Over to Commissioning		247
Lesson 13 - Summary and Theoretical Test		248
ELEMENT 13.1 - Summary		248
ELEMENT 13.2 - Theoretical Test		248
Lesson 14 - Training Review		249
ELEMENT 14.1 - Training Review		249
ELEMENT 14.2 - Feedback Session		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

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