1 Table of contents 262

2023-05-02_BTT_V8

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		12
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		13
6.2 Handouts		13
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		21
ELEMENT 1.2 - Facilities		22
ELEMENT 1.3 - Introduction		22
ELEMENT 1.4 - Aims and Objectives		23
ELEMENT 1.5 - Ongoing Assessments		23
ELEMENT 1.6 - Motivation		24
ELEMENT 1.7 - Human factors		24
Lesson 2 - Mechanical Introduction		25
ELEMENT 2.1 - Main Components of the Structure		25
ELEMENT 2.2 - Main Mechanical Systems		26
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		29
ELEMENT 3.4 - The Importance of Appropriate Isolation		30
Lesson 4 - The Principles of Bolted and Welded Connections		30
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		32
ELEMENT 4.4 - Bolt Connections and Correct Tightening Tools		33
Lesson 5 - Use of Manual Tightening and Measuring Tools		33
ELEMENT 5.1 - Metric System		34
ELEMENT 5.2 - Selecting and Using the Correct Manual Tightening Tools		34
ELEMENT 5.3 - Correctly Setting and Using a Torque Wrench		35
ELEMENT 5.4 - Feeler Gauges		36
ELEMENT 5.5 - Callipers		36
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		39
ELEMENT 7.1 - The Function of the Mechanical and the Aerodynamic Brakes		39
ELEMENT 7.2 - Inspection of the Mechanical Brake System		41
Lesson 8 - Yaw System		41
ELEMENT 8.1 - The Function of the Yaw System		41
ELEMENT 8.2 - Inspection of the Yaw System		42
Lesson 9 - Cooling System		43
ELEMENT 9.1 - The function of the Cooling System		43
ELEMENT 9.2 - Inspection of the Cooling System		44
Lesson 10 - Lubrication System		45
ELEMENT 10.1 - Components Requiring Lubrication, and Why		45
ELEMENT 10.2 - Inspection of Lubrication Systems		46
Lesson 11 - Summary and Theoretical Test		47
ELEMENT 11.1 - Summary		47
ELEMENT 11.2 - Theoretical Test		47
Lesson 12 - Training Review		48
ELEMENT 12.1 - Training Review		48
ELEMENT 12.2 - Feedback Session		48
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		57
Lesson 2 - Introduction to Electricity		58
ELEMENT 2.1 - Direct Current		58
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		64
ELEMENT 3.6 - Safety Signs		65
ELEMENT 3.7 - Types of PPE		65
ELEMENT 3.8 - The Importance of Appropriate Isolation		66
Lesson 4 - Electrical Components		67
ELEMENT 4.1 - Resistors		67
ELEMENT 4.2 - Batteries		67
ELEMENT 4.3 - Switches		68
ELEMENT 4.4 - Contactors		69
ELEMENT 4.5 - Relays		69
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		72
ELEMENT 4.11 - Fuses and Circuit Breakers		73
ELEMENT 4.12 - Processor Control Systems		74
Lesson 5 - Sensors		74
ELEMENT 5.1 - Introduction to Sensors		74
ELEMENT 5.2 - Wind Sensors		75
ELEMENT 5.3 - Temperature Sensors		75
ELEMENT 5.4 - Position Sensors		76
ELEMENT 5.5 - Other Sensors		77
Lesson 6 - Electrical Circuits		77
ELEMENT 6.1 - Symbols and Diagrams		77
ELEMENT 6.2 - Assembly of an Electrical Circuit		78
Lesson 7 - Electrical Measuring Instruments		78
ELEMENT 7.1 - Symbols and Settings on Electrical Measuring Instruments		79
ELEMENT 7.2 - How to Measure with Electrical Measuring Instruments		79
ELEMENT 7.3 - Measuring Points		80
Lesson 8 - Summary and Theoretical Test		81
ELEMENT 8.1 - Summary		81
ELEMENT 8.2 - Theoretical Test		81
Lesson 9 - Training Review		82
ELEMENT 9.1 - Training Review		82
ELEMENT 9.2 - Feedback Session		82
11. The BTT Hydraulic Module		84
11.1 Aims and Objectives of the BTT Hydraulic Module		84
11.2 Duration of the BTT Hydraulic Module		84
11.3 BTT Hydraulic Module Participant Ratio		85
11.4 Equipment		85
11.5 BTT Hydraulic Module Timetable		85
11.6 Detailed description of the BTT Hydraulic Module		87
Lesson 1 - Introduction		87
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		88
ELEMENT 1.2 - Facilities		88
ELEMENT 1.3 - Introduction		89
ELEMENT 1.4 - Aims and Objectives		89
ELEMENT 1.5 - Ongoing Assessments		90
ELEMENT 1.6 - Motivation		90
ELEMENT 1.7 - Human factors		91
Lesson 2 - Hydraulic Introduction		92
ELEMENT 2.1 - The Hydraulic System		92
ELEMENT 2.2 - Pascal’s Law		92
Lesson 3 - Hydraulic Safety		93
ELEMENT 3.1 - Why Hydraulic Safety		93
ELEMENT 3.2 - High Pressure Systems		94
ELEMENT 3.3 - Stored Energy		95
ELEMENT 3.4 - Safety Signs		95
ELEMENT 3.5 - Chemicals		96
ELEMENT 3.6 - Types of PPE		96
ELEMENT 3.7 - Importance of Appropriate Isolation		97
Lesson 4 - Pumps		98
ELEMENT 4.1 - Introduction to Pumps		98
ELEMENT 4.2 - Pumps Exercise		99
Lesson 5 - Actuators		99
ELEMENT 5.1 - Introduction to Actuators		99
Lesson 6 - Valves		100
ELEMENT 6.1 - Introduction to Valves		100
ELEMENT 6.2 - Directional Control Valves		101
ELEMENT 6.3 - Pressure Relief Valves		102
ELEMENT 6.4 - Pressure Reduction Valves		103
ELEMENT 6.5 - Needle Valves		103
ELEMENT 6.6 - Non-return Valves		104
ELEMENT 6.7 - Throttle Valves		105
ELEMENT 6.8 - Restrictor Valves		105
Lesson 7 - Accumulators		106
ELEMENT 7.1 - Introduction to Accumulators		106
ELEMENT 7.2 - Pre-charge Pressure		107
Lesson 8 - Sensors		108
ELEMENT 8.1 - Introduction to Sensors		108
ELEMENT 8.2 - Pressure Sensors		108
Lesson 9 - Pipes, Hoses and Connections		109
ELEMENT 9.1 - Oil Transfer		109
ELEMENT 9.2 - Hydraulic Connections		110
Lesson 10 - Oil and Filters		111
ELEMENT 10.1 - Procedures for Handling of Oil		111
ELEMENT 10.2 - Collecting and Oil Sample		111
ELEMENT 10.3 - Checking Oil Levels		112
ELEMENT 10.4 - Filters		112
Lesson 11 - Hydraulic Diagrams		113
ELEMENT 11.1 - Symbols and Diagrams		113
ELEMENT 11.2 - Identifying Measuring Points		114
Lesson 12 - Pressure Measuring Tools		115
ELEMENT 12.1 - Pressure Gauge/Manometer		115
ELEMENT 12.2 - Pressure Measurement		116
Lesson 13 - Summary and Theoretical Test		116
ELEMENT 13.1 - Summary		116
ELEMENT 13.2 - Theoretical Test		117
Lesson 14 - Training Review		117
ELEMENT 14.1 - Training Review		117
ELEMENT 14.2 - Feedback Session		118
12. The BTT Bolt Tightening Module		120
12.1 Aims and Objectives of the BTT Bolt Tightening Module		120
12.2 Duration of the Bolt Tightening Module		120
12.3 BTT Bolt Tightening Participant Ratio		120
12.4 Participant Prerequisites for the BTT Bolt Tightening Module		121
12.5 Developing Training Scenarios for this Module		121
12.6 Equipment		124
12.7 BTT Bolt Tightening Module Timetable		124
12.8 Detailed Description of the BTT Bolt Tightening Module		126
Lesson 1 - Introduction to the Module		126
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		127
ELEMENT 1.2 - Facilities		127
ELEMENT 1.3 - Introduction		128
ELEMENT 1.4 - Aims and Objectives		128
ELEMENT 1.5 - Ongoing Assessments		129
ELEMENT 1.6 - Motivation		129
ELEMENT 1.7 - Human Factors		130
Lesson 2 - Bolt Tightening in the Wind Industry		131
ELEMENT 2.1 - Limitations of the Training		131
ELEMENT 2.2 - Recap of the BTT Mechanical		132
ELEMENT 2.3 - Bolt Tightening Theory		133
ELEMENT 2.4 - Quality Assurance in Bolt Tightening		134
Lesson 3 - Framing the Scenario: Bolt Torquing Using Energy Powered Tools		135
ELEMENT 3.1 - Introduction to Bolt Torquing in the Wind Industry Using Energy Powered Tools and Accessories		135
ELEMENT 3.2 - Attitude Requirements for Working with Energy Powered Torquing Tools and Accessories		138
Lesson 4 - Pre-Task Phase: Planning and Preparation		138
ELEMENT 4.1 - Planning the Task		139
ELEMENT 4.2 - Preparing for the Task		141
ELEMENT 4.3 - Planning for Safety		142
Lesson 5 - The Task Phase: Safely and Correctly Torquing Bolts Using Electrical and Hydraulic Tools		144
ELEMENT 5.1 - Setting Up Equipment for Use		144
ELEMENT 5.2 - Bolt Torquing		145
ELEMENT 5.3 - Bolt Loosening		146
ELEMENT 5.4 - Safety, Quality and Trouble Shooting		147
Lesson 6 - Post-task Phase: Pack Up and Review		148
ELEMENT 6.1 - Post-use Inspection and Packing		149
ELEMENT 6.2 - Post-Job Documentation		149
Lesson 7 - Framing the Scenario: Bolt Tensioning Using Energy Powered Tools		150
ELEMENT 7.1 - Introduction to Bolt Tensioning in the Wind Industry Using Energy Powered Tools and Accessories		151
ELEMENT 7.2 - Attitude Requirements for Working with Energy Powered Tensioning Tools and Accessories		153
Lesson 8 - Pre-Task Phase: Planning and Preparation		154
ELEMENT 8.1 - Planning the Task		154
ELEMENT 8.2 - Preparing for the Task		156
ELEMENT 8.3 - Planning for Safety		157
Lesson 9 - The Task Phase: Safe and Correct Tensioning of Bolts Using Hydraulic Tools		159
ELEMENT 9.1 - Setting Up Equipment for Use		160
ELEMENT 9.2 - Bolt Tensioning		161
ELEMENT 9.3 - Bolt Loosening		162
ELEMENT 9.4 - Safety, quality and trouble shooting		163
Lesson 10 - Post-Task Phase: Pack Up and Review		164
ELEMENT 10.1 - Post-use Inspection and Packing		164
ELEMENT 10.2 - Post-job Documentation		165
Lesson 11 - Using Mechanical Handling Aids to Assist with Bolt Tightening Tasks		166
ELEMENT 11.1 - Mechanical Handling Aids Typically Used in the Wind Industry		166
ELEMENT 11.2 - Using Mechanical Handling Aids		167
ELEMENT 11.3 - Hazards Associated with Using Mechanical Handling Aids		168
ELEMENT 11.4 - Mitigating Hazards Associated with Mechanical Handling Aids		169
Lesson 12 - Training Review		170
ELEMENT 12.1 - Training Review		170
ELEMENT 12.2 - Feedback Session		171
13. The BTT Installation Module		174
13.1 Aims and Objectives of the BTT Installation Module		174
13.2 Duration of the BTT Installation Module		174
13.3 BTT Installation Participant Ratio		175
13.4 Participant Prerequisites for the BTT Installation Module		175
13.5 Equipment		175
13.6 BTT Installation Module Timetable		175
13.7 Detailed Description of the BTT Installation Module		178
Lesson 1 - Introduction		178
ELEMENT 1.1 - Safety Instructions and Emergency Procedures		178
ELEMENT 1.2 - Facilities		179
ELEMENT 1.3 - Introduction		179
ELEMENT 1.4 - Aims and objectives		180
ELEMENT 1.5 - Ongoing Assessments		180
ELEMENT 1.6 - Motivation		181
ELEMENT 1.7 - Human Factors		181
Lesson 2 - Introduction to Installation		182
ELEMENT 2.1 - Installation overview		182
ELEMENT 2.2 - Why Installation Safety		183
ELEMENT 2.3 - Safety Signs		185
ELEMENT 2.4 - Types of PPE		185
ELEMENT 2.5 - The Importance of Appropriate Isolation		186
Lesson 3 - General Procedures for Working Onsite with Installation		186
ELEMENT 3.1 - Checklist, Work Instructions, Etc.		186
ELEMENT 3.2 - Housekeeping		187
Lesson 4 - Installation Environments		188
ELEMENT 4.1 - Installation Environments		188
Lesson 5 - Handling and Storing		189
ELEMENT 5.1 - Risks and Hazards Associated with Handling and Storing		189
ELEMENT 5.2 - Reception/Inspection		190
ELEMENT 5.3 - Unloading and Storage of Blades, Nacelle, Tower Sections and Hub		191
ELEMENT 5.4 - Tools and Equipment		192
ELEMENT 5.5 - Returning Goods and Components		192
Lesson 6 - Lifting Operations		193
ELEMENT 6.1 - Types of Lifting		193
ELEMENT 6.2 - Risks and Hazards Associated with Lifting Operations		195
ELEMENT 6.3 - Roles and Responsibilities		196
Lesson 7 - Main Component Preparation, Pre-assembly and Assembly		197
ELEMENT 7.1 - Preparation, Pre-assembly and Assembly		197
ELEMENT 7.2 - Risks and Hazards Associated with Main Component Preparation, Pre-assembly and Assembly		198
ELEMENT 7.3 - Challenges When Assembling Main Components		199
Lesson 8 - Principles of Mechanical Completion		200
ELEMENT 8.1 - Introduction to Mechanical Completion		200
ELEMENT 8.2 - Examples of Mechanical Completion		200
ELEMENT 8.3 - Risks and Hazards Associated with Mechanical Completion		201
Lesson 9 - Principle of Electrical Completion		202
ELEMENT 9.1 - Introduction to Electrical Completion		202
ELEMENT 9.2 - Examples of Electrical Completion		202
ELEMENT 9.3 - Risks and Hazards Associated with Handling and Working with Cables		203
ELEMENT 9.4 - Different Types of Cables		204
ELEMENT 9.5 - Simple Installation Diagrams		204
ELEMENT 9.6 - Cutting and Crimping Cables		205
ELEMENT 9.7 - Marking, Routing and Termination of all Cable Types		206
Lesson 10 - Principles of Hydraulic Completion		209
ELEMENT 10.1 - Introduction to Hydraulic Completion		209
ELEMENT 10.2 - Examples of Hydraulic Completion		209
ELEMENT 10.3 - Risks and Hazards Associated with Hydraulic Completion		210
Lesson 11 - Principles of Operation with External Generators		211
ELEMENT 11.1 - Principles of Yaw, Rotor and Blade Operation without Grid-power		211
ELEMENT 11.2 - Risks and Hazards Associated with the Operation of Auxiliary Systems with External Generators		212
ELEMENT 11.3 - Preconditions for the Operation of Lifts with an External Generator		213
ELEMENT 11.4 - Preconditions for Operation of Internal Cranes with an External Generator		213
ELEMENT 11.5 - Use of External Generators for Other Auxiliary Uses		215
Lesson 12 - Introduction to Handover to Commissioning		215
ELEMENT 12.1 - Handover to Commissioning		216
ELEMENT 12.2 - Risks and Hazards Associated with Handing Over to Commissioning		216
Lesson 13 - Summary and Theoretical Test		217
ELEMENT 13.1 - Summary		217
ELEMENT 13.2 - Theoretical Test		217
Lesson 14 - Training Review		218
ELEMENT 14.1 - Training Review		218
ELEMENT 14.2 - Feedback Session		218
Annex 1 - Equipment list		221
Annex 2 - Scenario documents: Bolt torquing		228
Annex 3 - Scenario documents: Bolt tensioning		242
Annex 4 - Version History		256

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