GWO Blade Repair v1

GLOBAL WIND ORGANISATION

TRAINING STANDARD

Basic Blade Repair Training (Onshore/Offshore)

Version 1 April 2019

GWO BLADE REPAIR TRAINING STANDARD V01

1 LIST OF ABBREVIATIONS ................................................................................. 4

2 TERMS AND DEFINITIONS ................................................................................ 5

3 CHANGE LOG.................................................................................................. 6

4 SCOPE........................................................................................................... 7

5 GENERAL REQUIREMENT TO GWO BLADE REPAIR ................................................ 8 5.1 Target group .........................................................................................................8 5.2 Aims and strategic objectives ..................................................................................8 5.3 Conformity with other Training ................................................................................8 5.4 Legal requirements ................................................................................................8 5.5 Guidance on delivering lesson elements....................................................................9 5.6 Validity Period .......................................................................................................9 5.7 Delegate prerequisites for the Blade repair module ....................................................9 5.8 Physical demands ..................................................................................................9 6 GENERAL RESOURCES REQUIRED TO DELIVER BLADE REPAIR MODULE ................ 10 6.1 Staff ..................................................................................................................10 6.2 Facilities and Equipment .......................................................................................10 6.3 Theory training facilities .......................................................................................10 6.4 Practical training facilities .....................................................................................10 6.5 Training Equipment..............................................................................................11 8 ADMINISTRATION AND CERTIFICATION OF MODULES ........................................ 14 8.1 Administrative arrangements ................................................................................14 8.2 Delegate performance assessment.........................................................................14 8.3 Requirement to upload training record in WINDA .....................................................15 8.4 Training Providers Own Records and Certificates issue..............................................15 9 MODULE - BLADE REPAIR ............................................................................... 16 9.1 Aims and objectives of the Blade Repair Module .........................................................16 9.2 Duration of the Blade repair module .......................................................................17 9.3 Blade repair module Trainer/Delegate Ratio ............................................................17 9.4 Blade Repair module Timetable .............................................................................17 9.5 Detailed description of the blade repair module .......................................................19 Introduction ..................................................................................................19 Safety Data sheets .........................................................................................21 work instruction .............................................................................................22 risk assessment .............................................................................................23 secure an area ...............................................................................................25 contamination................................................................................................25 waste segregation ..........................................................................................26 ergonomic .....................................................................................................27 lock out tag out..............................................................................................28 personal protective equipment .......................................................................29 masks and filters ..........................................................................................31 10 TOPIC 2 - GENERAL KNOWLEDGE .................................................................... 33 chemical safety ............................................................................................33 Composites and blade construction .................................................................34 materials .....................................................................................................37 tools and equipment .....................................................................................40 Phase test ...................................................................................................44 Lamination skills...........................................................................................45 7 UNDERSTANDING GWO LEARNING OBJECTIVES ................................................ 12 7.1 Taxonomy ..........................................................................................................12

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Basic Lamination ..........................................................................................49 Sandwich panel ............................................................................................52 painting.......................................................................................................57 Blade inspection ...........................................................................................58 Inspecting lightening protection system...........................................................62 Grinding skills ..............................................................................................63 sanding skills ...............................................................................................64 laminate repairs ...........................................................................................65 filling ..........................................................................................................70 surface repairs .............................................................................................71 trailing edge repairs ......................................................................................73 leading edge repairs .....................................................................................76 Sandwich panel repair ...................................................................................77 Bond line repairs ..........................................................................................80 summary and Final test .................................................................................81 Evaluation ...................................................................................................82 reflection session..........................................................................................82 formative evaluation .....................................................................................83 1. Documentation: .....................................................................................................86 2. Measuring Tools (enough for each delegate):.............................................................86 3. Power tools (enough for each delegate) ....................................................................86 4. Hand tools (enough for each delegate)......................................................................87 5. Tools consumables .................................................................................................87 6. Consumable materials: ...........................................................................................87 7. Personal Protective Equipment .................................................................................88 1. Introduction: .........................................................................................................90 2. Exercise 1 - Mould preparation.................................................................................91 3. Exercise 2 - Gelcoat ...............................................................................................91 4. Exercise 3 - Dry material preparation .......................................................................92 5. Exercise 4 - Matrix material .....................................................................................92 6. Exercise 5 - Panel assembly ....................................................................................93 7. Exercise 6 - curing .................................................................................................93 PRACTICAL EXERCISE (EXAMPLE) ............................................................... 90 DELEGATE ASSESSMENT FORM .................................................................. 84 MEDICAL SELF-ASSESSMENT FORM ............................................................ 85 EQUIPMENT LIST ..................................................................................... 86

WORK INSTRUCTION (EXAMPLE) ................................................................ 94

PHOTOCARD.......................................................................................... 100

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1 L IST OF A BBREVIATIONS

GWO

Global Wind Organisation

WINDA

GWO training record database

SDS

Safety Data Sheet

PPE

Personal Protective Equipment

LOTO

Lock out Tag Out

TDS

Technical Data Sheet

TG

Glass Transition

CS

Chopped Strand

UD

Unidirectional

Biax

Biaxial

Triax

Triaxial

WI

Work Instructions

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GWO BLADE REPAIR TRAINING STANDARD V01

2 T ERMS AND D EFINITIONS

Hardback

A thin, pre-cured sheet of fibre reinforce composite material. Usually consisting of 1 layer of 600 gsm biax glass fibre.

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GWO BLADE REPAIR TRAINING STANDARD V01

3 C HANGE LOG

Amendment Date

Approved by & date

Version

Description of changes

Amendment Date

05/02/2019 Approved by & date GWO SC 05/02/2019

Version

1

Description of changes

Minor corrections since launch

October 2019

- Section 9.2 duration updated to clarify meaning of contact time

First Edition

New Training Module created

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GWO BLADE REPAIR TRAINING STANDARD V01

4 S COPE

The Global Wind Organisation (GWO) is an association of wind turbine owners and manufacturers with the aim of supporting an injury-free work environment in the wind industry. An objective of the GWO is to develop common industry training and best practice standards for health and safety as a vital and necessary way forward to reduce risks for personnel in the wind industry working on site and to reduce environmental risks around the globe. This Standard has been developed in response to the demand for recognizable blade repair training in the industry. It has been prepared in cooperation with the members of GWO based on specific risk assessments, data from incident and accident statistics pertaining to the installation, service and maintenance of blades on wind turbine generators and wind power plants. This standard describes the requirements for blade repair training that are recommended by the members of the GWO. The members of the GWO recognize trained persons as competent within blade repair in the wind industry and accept the trained person as possessing the required knowledge to stop an unsafe work situation where they as duty-holders are accountable for safety. Training is verified through the GWO database WINDA. Where national legislation sets higher requirements for the specific training, the training provider shall incorporate these requirements into the training program.

Additional training may be required for company or country specific reasons.

This standard has been developed by the GWO training committee. Disputes and potential non-conformities must be brought to the attention of the GWO audit and compliance committee.

This standard has been approved by the GWO Steering Committee.

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GWO BLADE REPAIR TRAINING STANDARD V01

5 G ENERAL R EQUIREMENT TO GWO BLADE REPAIR

Upon completion of the GWO Blade repair module (BR), delegates will be aware of the risks and hazards encountered when working with blade inspection and repair within the wind industry. Furthermore, they will be able to control and mitigate those risks and hazards. The GWO blade repair training module will also equip participants with the knowledge, skills and confidence to appropriately respond in the event of a hazardous situation and to increase their safety through proper use of personal protective equipment, emergency equipment, procedures and safe craftsmanship.

5.1 Target group

Personnel who will be working in the wind industry specifically in relation to composite inspection and repair work. Personnel that perform job functions that have been risk assessed by their employer or their workplace duty holder as a function, where composite work training according to this standard may mitigate some of the identified hazards and risks.

5.2 Aims and strategic objectives

Training in accordance with this standard will enable delegates to support and care for themselves and others working in the wind industry by possessing the knowledge and skills of composite inspection and repair work. Upon completion of the GWO Blade repair training course, delegates will be able to work safely with composite materials while conducting inspection and basic blade repair procedures, thereby supporting an overall improvement of the safety for personnel with job functions focussing on composite repair work and inspection in the wind industry.

5.3 Conformity with other Training

The GWO Blade repair training standard sets out minimum requirements.

The modules, learning objectives, lessons and elements may be delivered in the order that fits best for the specific training situation. Provided that the minimum requirements of this blade repair training standard are satisfied, the training provider may choose to incorporate delivery of other similar certified training.

5.4 Legal requirements

The training provider must identify whether national legislation sets additional requirements for blade repair training or prohibits delivery of certain elements. If so, the training provider must incorporate these identified requirements in the training.

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5.5 Guidance on delivering lesson elements

Section 10.4 gives approximate duration of each of the lessons. The training provider may choose to deliver elements of the training according to other timetables, provided that the total duration is not reduced, and the duration of practical elements are not reduced in length. Theoretical elements should be delivered during the practical exercises whenever feasible.

5.6 Validity Period

The blade repair training is an enduring qualification and therefore a validity period does not apply to this training. This assumes that the delegate is actively working with composite inspection and repair.

5.7 Delegate prerequisites for the Blade repair module

All personnel participating in the blade repair training module shall be medically fit and capable of fully participating. Specifically, the delegates must be made aware of the risks and hazards related to completing this course while being allergic towards the materials used in the module. Furthermore, this also applies for delegates suffering from asthma and hyperhidrosis manuum (excessive hand sweating). Training providers shall have a procedure that requires delegates to sign a statement stating that they are medically fit to participate in the training course and that they do not suffer from any medical illness that will prevent them from fully participating in the training course or subject them to hazard or risk, or are under the influence of any impeding substances like narcotics or alcohol. The Annex 2: Medical Self-Assessment Form shall be used if no other equivalent procedure is in place. Delegates’ signatures testifying to their medical fitness shall be collected prior to the start of the GWO blade repair module. Delegates must have created a personal delegate profile in WINDA and provide their own WINDA ID prior to completing the GWO blade repair training.

5.8 Physical demands

The GWO blade repair training module may potentially be physically demanding.

If there is any doubt regarding the medical fitness of any delegate, the training provider shall stop training with the delegate and seek a physician’s advice. Note: Practical exercises shall be designed and delivered solely to meet this standard and shall not place any physical or mental demands on the delegates other than those required to meet this standard.

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GWO BLADE REPAIR TRAINING STANDARD V01

6 G ENERAL R ESOURCES REQUIRED TO DELIVER B LADE REPAIR M ODULE

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

6.1 Staff

Training staff shall possess appropriate qualifications and experience to ensure that all training and supportive activities are carried out in accordance with current legislation and the current requirements outlined on the CRITERIA FOR TRAINING PROVIDERS OFFERING GWO TRAINING document.

The Instructor must:

Hold valid certificates for GWO BST/BSTR First Aid and GWO BST/BSTR Manual Handling Be able to demonstrate knowledge and practical skills in blade repair methods, techniques and craftsmanship comparable to those executed by the delegates during the practical exercises of the Blade repair module

Act as first responder in the case of an accident

Supporting staff:

A person with a current valid first aid qualifications shall be present during all practical training. This can be the instructor or an assigned emergency response team

6.2 Facilities and Equipment

The full range of facilities and equipment relevant to the modules being delivered shall be available during the training. The following facilities criteria shall be adhered to. Turbine manufacturer specifics may limit the application of the training requiring additional methods, techniques and equipment.

6.3 Theory training facilities

Facilities shall be designed to enable each Delegate to see, hear and fully participate in the taught subject matter.

6.4 Practical training facilities

All facilities shall be maintained and where appropriate, inspected and tested in accordance with current national legislation and manufacturers’ specification. It is recommended that the facilities reach European standards.

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GWO BLADE REPAIR TRAINING STANDARD V01

Risk assessments shall be conducted and documented for all training facilities. The training provider shall hold the required permits to operate the facilities. The learning process is facilitated by comparable elements, comparing the training environment and the delegates’ working environment. Comparable elements enhance the application of what is learned. The practical training facilities and the training environment are therefore expected to incorporate as many comparable elements to a real wind turbine working environment as is reasonably practicable. The practical training facility should enable each delegate to individually and/or as part of a team, see, hear and practice the taught subject matter in such a way that it resembles the working practices in a real wind turbine environment.

The following training facility items will be required for the Blade repair training:

A workshop area, ensuring the following:

Sufficient dust extraction to ensure that the amount of dust in the air is kept below 10 milligrams per cubic metre

Sufficient filtration of extracted air to prevent environmental contamination

Sufficient exposure control measures to limit training staff and delegates to the exposure limits as stated in the safety data sheet for all materials being used Sufficient temperature and humidity control to ensure that all materials being used are used within the usage limits specified in the technical data sheet for those materials Sufficient segregation from classrooms and administrative areas to prevent cross contamination of chemicals The training provider must ensure that chemical waste is disposed of in accordance with national legislation. The training provider must provide a changing area between workshop areas and clean areas like classrooms and administration areas where delegates and staff can change their shoes to prevent contamination of clean areas with chemicals. The above are the minimum requirements, if national legislation and regulation supersedes this, then they must be followed. Sufficient waste segregation to prevent cross contamination

6.5 Training Equipment

The equipment required for training as listed in Annex 3 must be available and must fulfil national legal requirements in the country where the training is taking place.

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GWO BLADE REPAIR TRAINING STANDARD V01

7 U NDERSTANDING GWO L EARNING O BJECTIVES

The described learning objectives (expected learning outcome) are the foundation of the course contents and what the delegate performance assessment must be based upon. Traditionally learning objectives are prepared within three different domains of learning – knowledge, skills and attitude. A learning objective describes the expected learning outcome on completion of a module or a course, within one or more learning domains. If a learning objective is related to more than one domain of learning, e.g. knowledge and skills, one learning objective per learning domain is often prepared – to enable a better understanding of the learning objective. The training provider may apply teaching methods (didactics) that are appropriate to the course participants prior training, education and cultural backgrounds but should always aim to provide course participants ample possibility to perform hands-on demonstrations and learning reflection.

7.1 Taxonomy

To formulate a measurable learning objective, taxonomy is used to describe the level of expected learning outcome within a learning domain. As an example, belonging to the learning domain of knowledge, to have a delegate name or recognize something, as opposed to have them explain it in their own words, or even apply or demonstrate what they have learned – describes different performance levels, i.e. different taxonomy levels.

Different taxonomies are associated with different learning domains, for instance:

Knowledge: such as Bloom’s “cognitive taxonomy”

Intellectual knowledge, mental skills and procedures

Skills: such as Simpson’s “psychomotor taxonomy”

Physical skills, cognitive controlled and observable

Attitude: such as Krathwohl’s “affective taxonomy”

Attitude and feelings to the learning

When selecting a suitable taxonomy level, an action verb expresses the expected behaviour of the delegate, thus describing the taxonomy level of a learning objective. Action verbs are usually highlighted in bold in this standard. The table below presents the three learning domains within taxonomy level 1-3, provided with associated action verbs applicable in the learning objective wording, defining the taxonomy level. In the GWO training standard, the learning objectives are in general described as level 2 or 3.

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GWO BLADE REPAIR TRAINING STANDARD V01

Knowledge

Skills

Attitude

3 Application / Applying To use in a new situation.

Guided response Follows instructions to build a model. Using a tool after observing an expert demonstrate how to use it. Be able to demonstrate an activity to other learners. Can complete the steps involved in the procedure as directed. Action verbs Accomplish, Achieve, Calibrate, Complete, Control, Demonstrate, Perform, Refine, Show. Set Awareness or knowledge of the ability needed to use the skill. Carry out tasks from verbal or written instructions. Showing eagerness to assemble components to complete a task. Knows and acts upon a sequence of steps in a process. Action verbs Access, Build, Complete, Conduct, Execute, Implement, Operate, Perform, Recreate. Perception Watch instructor and repeat action, process or activity. Recognizing sounds or pictures that indicate certain functionalities. Estimate the event of a certain function and be prepared for it. Action verbs Attempt, Copy, Duplicate, Follow, Organize, Repeat, Sketch, Replicate, Reproduce.

Value Demonstrates belief in the company's described process. Shows the ability to solve problems. Informs management on matters that one feels strongly about. Decide worth and relevance of ideas and tasks. Action verbs Argue, Challenge, Confront, Complete, Debate, Criticize, Justify, Join, Propose. Respond Completing work assignments with high respect to the agreement. Participating in team problem solving activities. Question new ideas and concepts in order to fully understand them. Participate actively and respectfully in discussions. Showing enthusiasm. Action verbs Receive Listening to discussions of controversial issues with an open mind. Respecting the rights of others. Listen to others and remember their opinions. Be positive and creative to what is being taught. Action verbs Ask, be open to, Concentrate, Discuss, Focus, Follow, Listen, Reply, Take part. Assist, Contribute, Discuss, Present, Question, Report, Respond, Tell, Write.

Solving problems by applying acquired knowledge, facts, techniques and rules in a different way. Applying a procedure to a familiar or unfamiliar task. Using a manual to calculate and operate. Action verbs Apply, Change, Choose, Compute, Modify, Operate, Practice, Prepare, Schedule, Solve, Write. Construct a meaning from instructional messages, including oral, written and graphic communication. Demonstrating basic understanding of facts and ideas. Explain in your own words the steps of performing a complex task. Action verbs Classify, Distinguish, Estimate, Explain, Express, Give, Illustrate, rules, sequences, procedures, etc. Locating knowledge in long-term memory and retrieving relevant knowledge from long-term memory. Action verbs Arrange, Define, Describe, Find, Identify, List, Name, Outline, Recognize, Relate, Recall, Retrieve. Indicate, Locate, Predict, Summarize, Translate.

2 Comprehension / Understanding

1 Knowledge / Remembering Memory of facts, terminology,

Table 7-1 - Taxonomy used by GWO

Note: Higher taxonomy levels exist.

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GWO BLADE REPAIR TRAINING STANDARD V01

8 A DMINISTRATION AND CERTIFICATION OF MODULES

8.1 Administrative arrangements

Appropriate for the enrolment and certification of Delegates and all aspects of the delivery of training shall be in accordance with this Standard.

8.2 Delegate performance assessment

Delegates will be assessed by means of direct observation and supplementary oral questions where appropriate (formative evaluation). Furthermore, the delegate will be subjected to written phase tests after the theory elements, and again after the close of the training course. (Summative evaluation) 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. There shall be at least one question for each lesson in the module.

The written tests shall be conducted in accordance with the following criteria:

There shall be an instructor present in the room where written tests are being conducted for the entire duration of the written test

The delegates shall not communicate with each other during the test

The delegates shall not communicate with any persons via email, telephone, skype (or similar) or social media during the test The delegates shall be allowed to use training material, handouts and their own notes during the test Where a delegate does not understand the meaning of a question or a multiple- choice option, the training staff shall be allowed to help the delegate in understanding the meaning of the question or the multiple-choice options. The training staff shall not give the delegate the correct answers to any test questions The written test questions cannot be used during the training in such a way that the delegates could recognise that they will be test questions. Each delegate must answer at least 70% of written test questions correctly to pass the test. If a Delegate does not reach the passing criteria in written or observational tests, then the instructor shall discuss this with the delegate to find out the reason for not reaching the passing criteria. If the reason is due to a misunderstanding of a question or due to language difficulties, then the instructor can mark a question as correct provided that the delegate is able to demonstrate understanding of the lesson element being tested. This must be documented by the instructor and stored with the tests, control measures and evaluations for the course. Training Providers shall have a documented procedure in place for dealing with Delegates not meeting the stated learning objectives. There shall be a time limit of 1½ minutes per question

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GWO BLADE REPAIR TRAINING STANDARD V01

Throughout the entire GWO blade repair course the instructor will use the delegate assessment form (see annex 2) to evaluate the delegates knowledge and skills, with a high focus on evaluating the delegate’s safety awareness and craftsmanship skills. The instructor shall keep a delegate assessment form (or adaptation) for each delegate until the completion / evaluation of the blade repair training module. The delegate assessment form (or adaptation) is a final evaluation tool for the instructors to assess delegates during practical elements. It allows measurement of the number of violations regarding safety, competency or attitude. The delegate assessment form shall be used as a progressive evaluation tool to discuss the performance of a delegate in guiding them to success. It also serves as supporting documentation if a delegate passes or fails the module. If a delegate fails to meet the demands of the blade repair training module, they can attend a new blade repair training in accordance with the contractual agreement when ordering the training course. The re-entry point is dictated by the stage where the delegate stepped out of the course or where the instructor deems constructive. Training providers may adapt the delegate assessment form to other media. Training providers must have a documented procedure in place for dealing with delegates not meeting the stated learning outcomes.

8.3 Requirement to upload training record in WINDA

Training providers are responsible for uploading a record of training to WINDA, the GWO online database of training records. This must be done as soon as possible and no later than 10 working days after completion of the training program.

Each record shall contain the following:

Delegate’s WINDA ID

Course code

Course completion date

Course code:

Module

Course Code

Blade repair

BR

Table 8-3 - GWO blade repair module course code

8.4 Training Providers Own Records and Certificates issue

The Training Provider shall, in accordance with the GWO criteria for training providers, maintain their own records of delegates. Upon request from the GWO or any of the members of the GWO, the training provider shall be able to verify the training and competence records of any specific personnel either attending a course and/or performing training of a course by name and nationality.

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Training providers may issue other additional proof of training, e.g. as paper certificate or plastic cards. If the training provider chooses to do so, it is recommended (not a requirement) to include the delegate WINDA ID.

9 M ODULE - B LADE REPAIR

9.1 Aims and objectives of the Blade Repair Module

The aim of the GWO blade repair training module is to enable the delegate to support and care for themselves and others working in the wind industry by possessing the knowledge, skills and attitude of blade repair. Upon successful completion of the GWO blade repair training course, the delegate will be able to perform and document a wind turbine blade inspection, execute repair work in accordance with a work instruction while maintaining the aerodynamic profile and structural integrity in glass fibre reinforced composite parts of a wind turbine within the following dimensions:

Trailing edge repairs up to 1,5 m in length

Leading edge repairs up to 1,5 m in length

Laminate repairs down to core material

Core material replacement up to 200 cm²

Surface repair to paint and gelcoat

The GWO blade repair training course is intended as an entry level course and therefore the delegate will not be expected to perform repairs in major structural elements of blades like spars, spar caps and carbon fibre.

To successfully complete the GWO blade repair training the delegate must be able to:

Demonstrate awareness of the course content and the facilities involved to ensure a clear understanding of what is expected during the course (L2 - Knowledge & Attitude) Demonstrate the ability to work safely with applicable chemicals while utilizing the applicable personal protective equipment in a controlled manner throughout all phases of composite inspection and repair work (L3 - Skills) Explain typical types of composite construction, materials and the importance of surface finish relating to aerodynamic performance and efficiency (L2 - Knowledge) Distinguish between and work safely in a controlled manner with epoxy, polyester, polyurethane, vinyl ester, methacrylate, reinforcement materials and solvents related to composite inspection and repair work (L3 - Skill) Prepare, operate and maintain the correct tools and equipment, be it electrical or mechanical (L2 - Skill)

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GWO BLADE REPAIR TRAINING STANDARD V01

Demonstrate the ability to safely execute and document laminate, sandwich panel and surface layer repairs in accordance with a work instruction in glass fibre reinforced composite parts

9.2 Duration of the Blade repair module

The total contact time for completing this blade repair module is estimated to be 70 hours. This is based on the time estimate given in the module timetable.

The training provider must not exceed the times per day given in table 9-2 below.

The training provider must ensure that sufficient time is allowed for delegates with prior experience to share their experiences related to blade repair in a way that is constructive for the entire class.

Maximum duration per day

Contact time

8 hours

Total training day

10 hours

Table 9-2 - Maximum durations for training day

Note:

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

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

9.3 Blade repair module Trainer/Delegate Ratio

The ratio shown for theory sessions indicates the maximum number of delegates that can attend the course. The ratio shown for practical sessions indicates the maximum number of delegates to be supervised by one instructor during each activity.

Module

Session

Instructor – Delegate Ratio

Theory

1:12

Blade repair

Practical

1:6

Table 9-3 - GWO Blade Repair Instructor to delegate ratio

9.4 Blade Repair module Timetable

The training provider may choose the order in which to deliver the elements of this blade repair training module, provided that the order of delivery enables the delegate to safely execute all tasks and exercises given to them, and that all learning objectives are met. The approximate duration of each lesson is given in table 9-4 below. The training provider may choose to deliver elements of the training according to other timetables, provided that the total duration is not reduced, and practical elements are not reduced

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in length. Theoretical elements should be delivered during the practical exercises whenever feasible.

Approx. Duration

Topic

Lesson

1 General safety

1

Introduction

15 min.

2

Safety Data Sheet

15 min.

3

Work instruction

10 min.

4

Risk assessment

20 min.

5

Secure an area

10 min.

6

Contamination

15 min.

7

Waste Segregation

10 min.

8

Ergonomic

15 min.

9

Lock out tag out

10 min.

TOTAL

120 min.

2 Personal Protective Equipment

10 Personal Protective Equipment

100 min.

11 Masks and Filters

45 min.

TOTAL

145 min.

3 General Knowledge

12 Chemical Safety

90 min.

13 Composites and blade construction

60 min.

14 Materials

75 min.

15 Tools and equipment

40 min.

16 Phase test

30 min.

TOTAL

295 min.

4 Craftmanship

17 Lamination skills

150 min.

18 Basic lamination

290 min.

19 Sandwich panel

420 min.

20 Painting

120 min.

21 Blade inspection

230 min.

22 Lightning protection system inspection

50 min.

23 Grinding skills

45 min.

24 Sanding

45 min.

25 Laminate repairs

600 min

26 Filling

180 min.

27 Surface repairs

180 min.

28 Trailing edge repairs

440 min.

29 Leading edge repairs

440 min.

30 Sandwich panel repairs

180 min.

31 Bond line repairs

180 min.

32 End of course test

60 min.

33 Feedback

30 min.

TOTAL

3640 min.

GRAND TOTAL

4200 min.

Table 9-4 - GWO Blade repair module timetable

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9.5 Detailed description of the blade repair module

INTRODUCTION

15 min.

The aim of this lesson is to give the delegate the needed awareness of the course content and the facilities involved in order to ensure that all delegates are aware of what to expect and what is expected of them during the course.

After this lesson the delegate will be aware of the following:

Safety instructions and emergency procedures

Facilities

Introduction

Scope and main learning objectives

Ongoing assessment (Delegate Assessment Form)

Motivation

ELEMENT 1.1 - SAFETY INSTRUCTIONS AND EMERGENCY PROCEDURES

The Instructor shall explain :

Safety instructions according to internal procedures

Emergency procedures and emergency exits in the areas where the delegates can be expected to be located during the course

Site specific chemical safety rules and instructions

ELEMENT 1.2 - FACILITIES

The Instructor shall explain :

General description of the facilities at the training location (Administration, dining area, restrooms, toilets, etc.)

ELEMENT 1.3 - INTRODUCTION

The Instructor shall give :

A short introduction of themselves, including their backgrounds as instructors

Delegates shall give:

A short introduction of themselves, including job function and expected primary geographic work location

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The Instructor shall explain :

The programme of the blade repair training module, including breaks and meal times

ELEMENT 1.4 - SCOPE AND MAIN LEARNING OBJECTIVES

The Instructor shall explain :

The scope and main objectives of the blade repair training module

ELEMENT 1.5 - ONGOING ASSESSMENTS (DELEGATE ASSESSMENT FORM)

The Instructor shall explain :

The reasons for the ongoing assessment

The layout of the GWO delegate assessment form and how it will be used

ELEMENT 1.6 - MOTIVATION

The Instructor shall explain :

The importance of personal involvement in the course

The definition of and the need for blade inspection and repair

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GWO BLADE REPAIR TRAINING STANDARD V01

SAFETY DATA SHEETS

15 min.

The aim of the lesson is to give the delegate the knowledge, skills and attitude to be able to read, explain and apply the information obtained from a safety data sheet (SDS).

To successfully complete this lesson the delegate shall be able to:

Explain the origin, purpose and content of safety data sheets (L2 - Knowledge)

Explain where to locate the most up to date safety data sheet in the applicable language (L2 - Knowledge) Describe safety instructions according to internal and national procedures (L2 - Knowledge) Explain the different types of hazard labels and their implications, covering at least toxic, flammable and hazardous environment symbols (L2 - Knowledge) Demonstrate how to identify what type of personal protective equipment is to be used with the applicable chemical (L2 - Knowledge)

ELEMENT 2.1 - SAFETY DATA SHEETS

Training Staff shall:

Describe the requirement for chemical manufacturers to produce safety data sheets for the chemicals they produce

Explain the purpose of safety data sheets

Show examples and explain the contents of safety data sheets with emphasis on sections 1.4, 2, 4 and 5

ELEMENT 2.2 - SAFETY DATA SHEET LOCATION

Training Staff shall:

Explain how to locate safety data sheets

Explain how to find safety data sheets written in local languages

Delegates shall:

Demonstrate the ability to locate the safety data sheet

Demonstrate how to find the safety data sheet in the applicable language

ELEMENT 2.3 - SAFETY INSTRUCTIONS

Training Staff shall:

Explain how to locate company specific safety instructions

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GWO BLADE REPAIR TRAINING STANDARD V01

Explain the requirement to follow national safety procedures

Explain how to react in case of an accident

Delegates shall:

Explain safety instructions according to internal and national procedures

Explain how to react in case of an accident

Locate at least one example of a chemical from the safety data sheet which will be used during the course, including the mitigation steps

ELEMENT 2.4 - HAZARD LABELS AND SYMBOLS

Training Staff shall:

Show examples from a safety data sheet and explain the meaning of hazard identification labels and their implications Show examples of and explain the meaning of toxic, flammable and hazardous symbols

Delegates shall:

Be able to recognise toxic, flammable and hazardous symbols

Be able to recognise different types of safety label and explain their implications

ELEMENT 2.5 - PERSONAL PROTECTIVE EQUIPMENT

Training Staff shall:

Demonstrate how to identify the personal protective equipment to be used with a chemical from the safety data sheet

Delegates shall:

Demonstrate how to identify the personal protective equipment to be used with the applicable chemical from the safety data sheet

WORK INSTRUCTION

10 min.

The aim of the lesson is to give the delegate the knowledge and attitude to be able to explain the need to locate the correct company specific work instruction and the implications of not seeking the latest information from the Work instruction before initiating work.

To successfully complete this lesson the delegate shall be able to:

Explain the content and purpose of a work instruction (L2 - Knowledge)

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GWO BLADE REPAIR TRAINING STANDARD V01

Explain how to locate the most updated company specific work instruction (L2 - Knowledge & Attitude) Explain the risks and hazards associated with NOT working with an updated company specific work instruction (L2 - Knowledge & Attitude)

ELEMENT 3.1 - THE WORK INSTRUCTION

Training Staff shall:

Explain the reasons for using a work instruction during blade repair

Explain the risks and hazards posed by not following a work instruction

Show an example and explain the content of a work instruction

ELEMENT 3.2 - LOCATE WORK INSTRUCTION

Training Staff shall:

Explain how to locate the most updated company specific WI. To be obtained from site lead or a company representative

RISK ASSESSMENT

20 min.

The aim of the lesson is to give the delegate the knowledge, skills and attitude to be able to explain and use risk assessments.

To successfully complete this lesson the delegates shall be able to:

Explain the content and purpose of a risk assessment (L2 - Knowledge & Attitude) Explain how to locate the most updated company specific risk assessment (L2 - Knowledge & Attitude) Explain the risks and hazards associated with NOT working with an updated company specific risk assessment (L2 - Knowledge) Explain the characteristic of lightning strike, implications and mitigation (L2 - Knowledge & Attitude) Explain the effect of wind/temperature on an assigned task (L2 - Knowledge & Attitude)

ELEMENT 4.1 - THE RISK ASSESSMENT

Training Staff shall:

Explain the purpose of risk assessments

Show examples of and explain the contents of risk assessments

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GWO BLADE REPAIR TRAINING STANDARD V01

Delegates shall:

Explain the purpose and content of a risk assessment

ELEMENT 4.2 - LOCATE UPDATED RISK ASSESSMENT

Training Staff shall:

Explain how to locate the most updated company specific risk assessment. To be obtained from site lead or a company representative

Delegates shall:

Explain how to obtain the most updated company specific risk assessments

ELEMENT 4.3 - OUTDATED RISK ASSESSMENT

Training Staff shall:

Explain why it is important to have updated company specific risk assessments

Explain the risks and hazards associated with using outdated risk assessments

ELEMENT 4.4 - LIGHTNING STRIKES

Training staff shall:

Explain the characteristics of a lightning strike

Explain the risks, hazards and implications of a lightning strike

Explain how to mitigate the risks of lightning strikes, by leaving site or moving to a safe area on site

Delegates shall:

Describe how to avoid lightning strike

ELEMENT 4.5 - WIND/TEMPERATURE

Training staff shall:

Explain the effects of wind when completing a task on site, by considering the health and safety risks posed by high winds and wind chill Explain the effects of high and low temperature when completing a task on site, by considering the health and safety risks posed by high and low temperatures Explain how to mitigate the risks posed by wind and temperature when completing a task on site

The delegate shall:

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GWO BLADE REPAIR TRAINING STANDARD V01

Explain how to mitigate the health and safety risks posed by wind and temperature when completing a task on site

SECURE AN AREA

10 min.

The aim of the lesson is to give the delegate the knowledge, skills and attitude to be able to explain and demonstrate how to secure an area

To successfully complete this lesson the delegates shall be able to:

Explain how to find the procedures for securing a blade repair work area (L2 - Knowledge)

Demonstrate how to secure a blade repair work area (L2 - Skills & Attitude)

ELEMENT 5.1 - LOCATE PROCEDURES

Training staff shall:

Explain how to locate the specific information for securing a blade repair work area

ELEMENT 5.2 - SECURING AREA

Training staff shall:

Explain the reasons for securing a blade repair work area

Explain and demonstrate how to secure a blade repair work area

Delegates shall:

Explain how to locate specific information for securing a blade repair work area

Demonstrate the ability to secure a blade repair work area

CONTAMINATION

15 min.

The aim of the lesson is to give the delegate the knowledge, skills and attitude to be able to explain contamination characteristic, implications and mitigations.

To successfully complete this lesson the delegate shall be able to:

Explain contamination characteristics, implications and mitigations (L2 - Knowledge)

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