GWO BTT v5.1

Basic Technical Training (BTT)

V5.1

Publication date: October 1, 2019

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

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

3 CHANGE LOG – REVISION 5.1 ..............................................................................................................6

4 SCOPE ....................................................................................................................................................8

5 GENERAL REQUIREMENTS TO GWO TRAINING.....................................................................................9

5.1 O VERVIEW ..............................................................................................................................................9 5.2 T ARGET G ROUP .......................................................................................................................................9 5.3 A IMS AND O BJECTIVES .............................................................................................................................9 5.4 D URATION OF BTT M ODULES .....................................................................................................................9 5.5 V ALIDITY P ERIOD ...................................................................................................................................11 5.6 C OURSE C ODES ....................................................................................................................................11 5.7 D ELEGATE P REREQUISITES FOR THE BTT......................................................................................................12 5.8 P HYSICAL D EMANDS ..............................................................................................................................12

6 GENERAL RESOURCES REQUIRED TO DELIVER BTT MODULES............................................................13

6.1 I NSTRUCTOR /D ELEGATE R ATIO ................................................................................................................13 6.2 P RACTICAL T RAINING F ACILITIES ..............................................................................................................13 6.3 E QUIPMENT ...........................................................................................................................................13 6.4 H ANDOUTS ...........................................................................................................................................13

7 UNDERSTAND GWO LEARNING OBJECTIVES .....................................................................................14

7.1 T AXONOMY ..........................................................................................................................................14

8 ADMINISTRATION AND CERTIFICATION ..............................................................................................17

8.1 D ELEGATE P ERFORMANCE A SSESSMENT ....................................................................................................17 8.2 C ONTROL M EASURES .............................................................................................................................18

9 MODULE 1 – THE BTT MECHANICAL MODULE ....................................................................................20

9.1 A IMS AND OBJECTIVES OF THE BTT M ECHANICAL M ODULE .........................................................................20 9.2 D URATION OF THE BTT M ECHANICAL M ODULE ..........................................................................................20 9.3 E QUIPMENT ...........................................................................................................................................21

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9.4 BTT M ECHANICAL M ODULE T IME T ABLE ....................................................................................................21 9.5 L EARNING OUTCOMES OF THE BTT M ECHANICAL M ODULE .........................................................................23

10 MODULE 2 - THE BTT ELECTRICAL MODULE .......................................................................................39

10.1 A IMS AND OBJECTIVES OF THE BTT E LECTRICAL M ODULE ...........................................................................39 10.2 D URATION OF THE BTT E LECTRICAL M ODULE ...........................................................................................39 10.3 E QUIPMENT .........................................................................................................................................40 10.4 BTT E LECTRICAL M ODULE T IMETABLE ......................................................................................................40 10.5 L EARNING OUTCOMES OF THE BTT E LECTRICAL M ODULE ...........................................................................42

11 MODULE 3 - THE BTT HYDRAULIC MODULE .......................................................................................57

11.1 A IMS AND OBJECTIVES OF THE BTT H YDRAULIC M ODULE ...........................................................................57 11.2 D URATION OF THE BTT H YDRAULIC M ODULE ............................................................................................57 11.3 E QUIPMENT .........................................................................................................................................58 11.4 BTT H YDRAULIC M ODULE T IME T ABLE .....................................................................................................58 11.5 L EARNING OUTCOMES OF THE BTT H YDRAULIC M ODULE ...........................................................................60

12 MODULE 4 - THE BTT INSTALLATION MODULE....................................................................................77

12.1 A IMS AND OBJECTIVES OF THE BTT I NSTALLATION M ODULE ........................................................................77 12.2 D URATION OF THE BTT I NSTALLATION M ODULE .........................................................................................77 12.3 D ELEGATE P REREQUISITES FOR THE BTT I NSTALLATION M ODULE ...................................................................78 12.4 E QUIPMENT .........................................................................................................................................78 12.5 BTT I NSTALLATION M ODULE T IME T ABLE ...................................................................................................78 12.6 L EARNING OUTCOMES OF THE BTT I NSTALLATION M ODULE ........................................................................81 C ONTROL M EASURE I NSTRUCTIONS ...............................................................................................107 E QUIPMENT LIST ..........................................................................................................................108 V ERSION H ISTORY .......................................................................................................................113

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1 List of Abbreviations

ANSI

American National Standards Institute

AS/NZS

Australia and New Zealand Standard

BTT

Basic Technical Training

BWH

Basic Working at Height

CO 2

Carbon Dioxide

CSA

Canadian Standards Association

EN

European Standards

GWO

Global Wind Organisation

LOTO

Lock Out Tag Out

PPE

Personal Protective Equipment

MES

Marine Evacuation Systems

WTG

Wind Turbine Generator

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2 Terms and Definitions

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

Demonstrate

Delegates have to prove he/she is able to apply the knowledge on a practice. Instructor has to create discussions involving the delegates.

Engage in discussions

Function

Purpose. What is it doing? What can it be used for?

Hazard

A hazard is any source of potential damage, harm or adverse health effects on something or someone.

Installation

1. 2. 3.

Preparation

Pre-assembly

Assembly

Operation

How does it work?

Practice Opportunity to apply knowledge received during a practice. Practice and demonstrate Opportunity to try coached by the instructor. Before

the end of the practice the delegate needs to prove he/she is able to perform the task without significant support from the instructor. A risk is the chance or probability that a person will be harmed or experience an adverse health effect if exposed to a hazard

Risk

Use

How to operate it? How to make it work?

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3 Change Log – Revision 5.1

Amendment Date

Oct. 2020

Approved by & date

Version

5.1

Description of changes

- GWO Standard updated to match the Corporate Visual identity of GWO (CVI) - Each module now contains a cover page and the module name listed in the header as reference. - New ISO Code added to standard - All previous versions of the Change log have now been moved to Annex XX. The current change log remains at the start of the standard. - Duplicate information removed from Section 4. Scope

The following sections have been removed due to this information now included in the new Requirements for Training Providers and Requirements for Certification Bodies (released May 2020)

Section 5

- 5.4 Conformity with other training – section removed - 5.5 Legal Requirements – Section Removed

Section 6

-

6.1 Instructors – section removed

- 6.3 Facilities and Equipment – section removed - 6.5 Theoretical training facilities – section removed

Section 8

- 8.1 Administrative arrangements – section removed - 8.4 Requirement to upload training record in WINDA – section removed (course Codes have now been moved to section 5.6) - 8.4 Training Providers own Records and Certificates issue – section removed

Annex 1

- Delegate Performance Assessment Form – Section removed

Annex 2

- Medical Assessment Form – Section removed

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All section reference numbers have now been updated

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4 Scope

This Standard has been developed in response to the demand for recognizable Basic Technical Training in the industry and has been prepared in co-operation between the members of GWO based on risk assessments and factual incident and accident statistics pertaining to the installation, service and maintenance of wind turbine generators and wind power plants. This Standard describes the requirements for Basic Technical Training courses that are recommended by the members of GWO. The standard covers 4 modules:

Hydraulic

Mechanical

Electrical

Installation

The members of the Global Wind Organisation (GWO) recognize trained persons as being able to safely perform basic hydraulics, mechanical , electrical and installation tasks under the supervision of an experienced technician. GWO members agree that everyone working on one of their properties (Wind Turbine Generators, sub stations, etc.) shall complete Basic Technical Training courses relevant for their assignments. All work shall be done in teams of at least 2 competent persons. Exemptions from the above can be made based on internal company rules. This standard has been developed by the GWO Training Committee. The standard was based on the EU-funded project “Adapting a Transparent Training Programme” completed in 2014.

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5 General Requirements to GWO Training

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

5.1 Overview

The GWO Basic Technical Training is divided into the following four Modules:

Hydraulic

Mechanical

Electrical

Installation

5.2 Target Group

The Basic Technical Training modules are targeted at candidates who have no previous experience of hydraulic, mechanical, electrical or installation systems but may also be used to up skill candidates who have some knowledge but not of their application in wind turbines.

5.3 Aims and Objectives

This BTT Training shall enable Delegates to be able to perform basic hydraulic, mechanical , electrical and installation tasks under the supervision of an experienced technician. This course will not make the Delegate a trained person who is allowed to perform hydraulic, mechanical, electrical or installation work without supervision.

5.4 Duration of BTT Modules

The total contact time for completing the stand-alone modules in this basic technical training standard is estimated to be 32 hours . This is based on the time estimates given in the module timetables and summarised in table 5-61 & 5-62 below.

The training provider must not exceed the times per day given in table 5-7 below.

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The training provider must ensure that sufficient time is allowed for delegates with prior experience to share their experiences related to the modules of the basic technical training standard in a way that is constructive for the entire class. Durations at the table below are meant to be an orientation for anyone delivering the training. Small variations are acceptable as far as they do not compromise reaching the objectives for all delegates. If the following modules are delivered as part of a complete training, the common elements of introduction and evaluation may be combined, reducing the total contact time. How this may be achieved is suggested in the timetables of each module.

Modules

Duration (*Effective time) As stand-alone training

Duration (*Effective time) As part of combined training

Mechanical

13,67 hours 9,92 hours 8,92 hours

13,67 hours 9,50 hours 8,50 hours 31,67 hours

Electrical Hydraulic

TOTAL

Table 5-41 - Duration of GWO BTT Modules

Modules

Duration (*Effective time) As stand-alone training

Duration (*Effective time) As part of combined training

Mechanical Installation

13,67 hours 17,67 hours

13,67 hours 17,25 hours 30,92 hours

TOTAL

Table 5-42 - Duration of GWO Mechanical and installation Modules

Maximum duration per day

Contact time

8 hours

Total training day

10 hours

Table 5-43 - Maximum durations for training days

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).

Within the module timetables, approximate duration of each of the lessons are given. The training provider may choose to deliver elements of the training according to other timetables, as long as the total duration is not reduced, and practical elements are not reduced in length. Theoretical elements may be delivered during the practical exercises when feasible. The practical skills shall be trained and demonstrated, and all elements of the course shall be covered by demonstration where possible.

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If the Mechanical, Electrical and Hydraulic modules are delivered as a combined training, the total contact time is estimated as at least 4 days of training (at least 31 hours 40 minutes effective training time). If the Mechanical and Installation modules are delivered as a combined training, the total contact time is estimated as at least 4 days of training (at least 30 hours 55 minutes effective training time).

If delivered as separate modules, the effective training time for each module is as follows:

The Mechanical module is estimated as a 2-day course (at least 13 hours and 40 minutes). The Electrical and Hydraulic modules are estimated as 1,5-day courses (at least 9 hours 55 minutes for the Electrical module and at least 8 hours 55 minutes for the Hydraulic module). The Installation module is estimated as a 2,5-day course (at least 17 hours and 40 minutes). It shall be ensured that everybody is given the opportunity to share their opinions and experiences where possible. Ensure that Delegates with prior experience share their experiences in a way that is constructive for the entire class. The BTT modules will still be taught as per the lesson plan whether the Delegate has prior experience or not.

5.5 Validity Period

The Basic Technical Training is an enduring qualification and therefore a validity period does not apply to this training. This is based on the assumption that the Delegate is actively working in a wind turbine environment. If there is an extended period of absence from applying the skills, retraining and recertification may be required according to national legislation and company policy. A maximum interval between successful completions of the BTT Hydraulic, Mechanical, Electrical and Installation Modules do not apply. This is based on the assumption that the Delegate is actively working in a wind turbine environment. If there is an extended period of absence from applying the skills, retraining and recertification may be required according to national legislation and company policy.

5.6 Course Codes

Module

Course Code

BTT Mechanical

BTTM

BTT Electrical

BTTE

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BTT Hydraulic

BTTH

BTT Installation

BTTI

Table 5-6 - GWO BTT module course codes

5.7 Delegate Prerequisites for the BTT

All personnel participating in Basic Technical Training shall be medically fit and capable of fully participating. Training providers shall have a procedure that requires Delegates to sign a statement stating that they are medically fit to participate in the safety training and that they do not suffer from any medical illness or are under influence of any narcotic substance or alcohol. The Requirements for Training Providers 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 Basic Technical Training course. Furthermore, Delegates shall have created a personal Delegate profile in WINDA and provide their own WINDA ID prior to completing the BTT training. There is only a prerequisite to attend the Installation module, hence, the Delegate must have completed the Mechanical Module before attending the Installation training. There are no prerequisites for the remaining modules, but some sort of practical mechanical or electrical maintenance background would be useful. Furthermore, personnel in the wind service industry must be able to read and write to a sufficient standard to be able to carry out instructions and complete the required documentation. It is an advantage if Delegates are able to read, speak and write English.

5.8 Physical Demands

BTT Modules do not have any specific anticipated physical demands.

However, if there is any doubt regarding the medical fitness of any Delegates, the Training Provider shall stop training 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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6 General Resources required to deliver BTT Modules

The Training Provider shall ensure that staff, facilities and equipment are in place to support the training of Delegates.

6.1 Instructor/Delegate Ratio

The ratio shown for the theory session indicates the maximum number of Delegates attending the course. Other ratios indicate the maximum number of Delegates to be supervised by an instructor during each activity.

Modules

Session

Instructor – Delegate Ratio

Theory

1:12

All BTT Modules

Practical

1:8

Table 6-1 - GWO BST Instructor to delegate ratios

6.2 Practical Training Facilities

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

6.3 Equipment

The equipment required for the delivery of the BTT modules is shown in Annex 1.

6.4 Handouts

Handouts must be given to the delegates containing as a minimum:

Electrical symbols mentioned in the BTT Standard

Hydraulic symbols mentioned in the BTT Standard

Formulas used (Pascal´s law, Ohm´s law, Torque…)

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

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7 Understand GWO Learning Objectives

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. to knowledge and skills, one learning objective per learning domain is often prepared – to enable a better understanding of the learning objective. The GWO Training Provider may apply teaching methods (didactics) that are appropriate to the course delegates prior training, education and cultural backgrounds, but should always aim to provide course delegates 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 to name or recognize something, as oppose to have him explain it in his own words, or even apply or demonstrate what he has 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

Selecting a suitable taxonomy level, an action verb expresses the expected behaviour of the delegate, thus describing the taxonomy level of a learning objective. The table below presents the three learning domains with taxonomy level 1-3, provided with associated action verbs applicable in the learning objective wording, defining the taxonomy level. In the Basic Technical Training standard, the learning objectives are in general described as level 2 or 3.

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Knowledge

Skills

Attitude

3 Application / Applying To use in a new situation. 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, Demonstrate, Modify, Operate, Practice, Prepare, Schedule, Solve, Write.

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.

Value Demonstrates belief in the company 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 highly respect to the agreement. Participating in team problem solving activities. Questions new ideas and concepts in order to fully understand them. Participate actively and respectful in discussions. Showing enthusiasm. Action verbs: Assist, Contribute, Discuss, Present, Question, Report, Respond, Tell, Write. Receive Listening to discussions of controversial issues with an open mind. Respecting the rights of others.

2 Comprehension / Understanding

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, Indicate, Locate, Predict, Summarize, Translate.

Action verbs: Access, Build,

Complete, Conduct, Execute, Implement, Operate, Perform, Recreate. Perception Watch instructor and repeat action, process or activity.

1 Knowledge / Remembering

Memory of facts, terminology, rules, sequences, procedures, etc.

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Locating knowledge in long-term memory and retrieving relevant knowledge from long- term memory. Action verbs: Arrange, Define, Describe, Find, Identify,

Recognizing sounds or pictures that indicate certain functionalities. Estimate the event of a certain function and be prepared for it. Action verbs: Attempt, Copy,

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.

List, Name, Outline, Recognize, Relate, Recall, Retrieve.

Duplicate, Follow, Organize, Repeat, Sketch, Replicate, Reproduce.

Table 7-1 - Taxonomy used by GWO

NOTE:

Higher taxonomy levels exist.

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8 Administration and Certification

8.1 Delegate Performance Assessment

Delegates shall be assessed separately on each module according to the learning objectives by means of direct observation during practices for level 3 objectives and written multiple choice questions on a test for level 1 and 2 objectives in order to be certified.

The multiple-choice test must be done in accordance to the following criteria:

At least 1 question per objective (level 1 and 2) with a minimum of 10 questions for each stand-alone module.

Time limit 1,5 minutes per question.

Test must be Individual.

Delegates can use:

a. Handouts.

b. Own notes.

Delegates cannot use:

a. Mobile phones (except for calculator).

The multiple-choice test questions cannot be used at any other time during the training in such a way that the delegates could recognize that they will be test questions at the end. The direct observation is to be conducted by practical scenarios on a WTG environment. Each Delegate shall demonstrate:

Assessment of learning objectives:

Correct use of appropriate PPE

Safe working procedures

Correct and proper methods of working

The formal evaluation of knowledge of practical scenarios shall be in accordance with the Control Measures below. At least 70% of the questions in the written test must be answered correctly in order to pass the corresponding module. In case of a Delegate failing the test, the instructor will have a discussion with the Delegate in order to find out the reason behind. If the reason was due to misunderstanding of a question or due to language the instructor can give for valid a question, as far as the Delegate demonstrates the right level of understanding. This must be properly documented by the instructor and kept together with the tests, control measures, evaluations...

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Training Providers shall have a documented procedure in place for dealing with Delegates not meeting the stated learning objectives. As part of the training process, Instructors shall perform an on-going assessment for the delegates asking questions or creating discussions in order to evaluate the progress of the training and make the necessary adjustments to ensure the learning objectives are being achieved.

8.2 Control Measures

A Template Control Measures form is provided in Requirements for Training Providers. The Training Provider may adapt the Control Measures Form to other media. The Trainer keeps a Control Measures Form (or adaptation) for each delegate until the completion / evaluation of the BTT Module. The Control Measures Form (or adaption) is a final evaluation tool for the instructors to assess Delegates during practical elements. It allows measurement of the number of violations in regard to safety, competency, or attitude. It shall be used as a progressive evaluation tool to discuss the performance of a Delegate in guiding them to success and it also serves as supporting documentation if a Delegate passes or fails the Module. If a Delegate fails to meet the demands of the BTT module, he/she will not be certified in the module.

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Mechanical Module

(BTTM)

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9 Module 1 – The BTT Mechanical Module

9.1 Aims and objectives of the BTT Mechanical Module

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

The BTT Mechanical Module shall ensure Delegates are able to:

Explain the main components, mechanical systems and the basic operation of wind turbines (L2 – Knowledge).

Explain risks and hazards associated with mechanics (L2 – Knowledge).

Understand the principles of bolted and welded connections and their inspection (L2 – Knowledge).

Demonstrate practical skills to use manual tightening and measuring tools (L3 – Skill).

Demonstrate the correct use of hydraulic torque and tensioning tools (L3 – Skill).

Explain the principles of a gearbox (L2 – Knowledge).

Explain the function of the brake systems and demonstrate how to inspect them (L2 – Knowledge / L3 – Skill). Explain the function of the yaw system and explain how to inspect it (L2 – Knowledge). Explain the function of the cooling system and demonstrate how to inspect it (L2 – Knowledge / L3 – Skill). Explain the function of the lubrication system and demonstrate how to inspect it (L2 – Knowledge / L3 – Skill).

9.2 Duration of the BTT Mechanical Module

The total contact time for completing this BTT mechanical module is estimated to be 13.67 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 the module in a way that is constructive for the entire class.

Maximum duration per day

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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 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.

9.4 BTT Mechanical Module Time Table

Within the module timetables, approximate duration of each of the lessons are given. The training provider may choose to deliver elements of the training according to other timetables, as long as the total duration is not reduced, and practical elements are not reduced in length. Theoretical elements may be delivered during the practical exercises when feasible.

The order in which the elements of the Training Module are delivered may vary.

Lesson

Element

Approx. Duration

1

Introduction

1.1

Safety instructions and emergency procedures

1.2

Facilities

1.3

Introduction

1.4

Aim and objectives

1.5

On-going assessment

1.6

Motivation TOTAL

30 min.

2

Mechanical introduction

2.1

Main components of the structure

2.2

Main mechanical systems

2.3

How a turbine works TOTAL

60 min.

3

Mechanical Safety 3.1

Why Mechanical Safety

3.2

Safety Signs

3.3

Types of PPE

3.4

The importance of appropriate isolation TOTAL

30 Min.

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4

The principles of bolted and welded connections

4.1

The principles of bolt connections

4.2

The locations of important bolted and welded connections

4.3

Inspection of welded connections

4.4

Bolt connections and correct tightening tools TOTAL

80 min.

5

Use of manual tightening and measuring tools

5.1

Metric System

5.2

Selecting and using the correct manual tightening tools

5.3

Correctly setting and using a torque wrench

5.4

Feeler gauges

5.5

Callipers

5.6

Dial gauge TOTAL

70 min.

6

Hydraulic Torque and Tension

6.1

Using a hydraulic torque wrench

6.2

Using a hydraulic tensioning tool TOTAL

300 min.

7

Gearbox

7.1

The function and operating principles

7.2

Inspection of the gearbox TOTAL

30 min.

8

Braking system

8.1

The function of the mechanical and the aerodynamic brake Inspection of the mechanical brake system TOTAL

8.2

40 min.

9

Yaw System

9.1

The function of the Yaw system

9.2

Inspection of the Yaw system TOTAL

30 min.

10 Cooling System

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

30 min.

11 Lubrication System 11.1 Components requiring lubrication and why 11.2 Inspection of the lubrication systems TOTAL

75 min.

12 Summary and Theoretical test

12.1 Summary 12.2 Theoretical test TOTAL

30 min.

13 Evaluation

13.1 Evaluation TOTAL

15 min.

GRAND TOTAL

820 min.

Table 9-4 – GWO BTT Mechanical module timetable

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9.5 Learning outcomes of the BTT Mechanical Module

The learning outcomes specified for the BTT Mechanical Module are:

INTRODUCTION

30 min.

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

ELEMENT 1.1 - SAFETY INSTRUCTIONS AND EMERGENCY PROCEDURES

Instructors shall:

Explain safety instructions according to internal procedures

Explain the emergency procedures and emergency exits in the localities the Delegates can be expected to be located during the course

ELEMENT 1.2 - FACILITIES

Instructors shall:

Give a General description of the facilities on the location (Administration, dining area, restrooms and toilets, etc.)

ELEMENT 1.3 - INTRODUCTION

Instructors shall:

Give a short presentation of himself including his background as an instructor

Delegates shall:

Give a short introduction, including job function expectation for the course

Instructors shall:

Explain the programme of the BTT, including breaks and meal times

ELEMENT 1.4 - AIM AND OBJECTIVES

Instructors shall:

Explain the aims and objectives of this BTT Training

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ELEMENT 1.5 - ON-GOING ASSESSMENTS

Instructors shall:

Explain the reasons for the on-going assessment

Explain the GWO Control Measures and their use

ELEMENT 1.6 - MOTIVATION

Instructors shall:

Explain the importance of personal involvement in the course

MECHANICAL INTRODUCTION

60 min.

The aim of this lesson is to give the Delegates an introduction to wind turbines.

To successfully complete this BTT Module, Delegates shall be able to:

Explain the main components in a wind turbine (L2 – Knowledge).

Explain the main mechanical systems in a wind turbine (L2 -Knowledge).

Explain how a wind turbine works (L2 – Knowledge).

ELEMENT 2.1 - MAIN COMPONENTS OF THE STRUCTURE

Instructors shall:

Explain the basic function and location of the:

a. Foundation & Transition piece

b. Tower sections

c. Nacelle

d. Rotor and blades

e. Platforms, ladders and lift

Delegates shall:

Engage in discussions about the main components of the structure of a wind turbine

ELEMENT 2.2 - MAIN MECHANICAL SYSTEMS

Instructors shall:

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Explain the basic function, main components and location of the:

a. Pitch system

b. Yaw system

c. Main shaft

d. Gearbox

e. Coupling

f.

Generator

Delegates shall:

Engage in discussions about the basic mechanical systems in a wind turbine

ELEMENT 2.3 - HOW A TURBINE WORKS

Instructors shall:

Explain how the turbine uses the wind to produce electricity

Define and explain wind speed and direction

Describe the basic aerodynamics of the blade

Explain control of the rotor speed using the blade regulation system

Delegates shall:

Engage in discussions about energy, wind speed and wind direction

MECHANICAL SAFETY

30 min.

The aim of this lesson is to give the Delegates the needed awareness, knowledge and understanding in order to handle mechanical hazards in a wind turbine.

To successfully complete this BTT Module, Delegates shall be able to:

Explain the importance of Mechanical Safety (L2 – Knowledge).

Identify Safety Signs (L1 – Knowledge).

Explain the required PPE for working with mechanics (L2 – Knowledge)

Explain the importance of proper isolation when working with mechanics (L2 – Knowledge).

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ELEMENT 3.1 - WHY MECHANICAL SAFETY

Instructors shall:

Explain the safety risks and hazards in mechanical systems (e.g. bruises, squeezing, rotation, fluids, trapping, slipping, pinching)

Explain the importance of working according to approved working practices

Explain the need for Safety Data Sheets (SDS)

Delegates shall:

Engage in discussions about safe working procedures, identifying the necessary PPE and appropriate tools

ELEMENT 3.2 - SAFETY SIGNS

Instructors shall:

Explain how to identify different signs for Mechanical Danger

Show examples of safety signs on different locations in the WTG

Delegates shall:

Engage in discussions about different safety signs’ meanings

ELEMENT 3.3 - TYPES OF PPE

Instructors shall:

Explain and demonstrate examples of usage and the inspection of PPE suitable for mechanical work

ELEMENT 3.4 - THE IMPORTANCE OF APPROPRIATE ISOLATION

Instructors shall:

Explain the importance of using appropriate isolation techniques when working with mechanics

Explain the importance of emergency stop buttons in the wind turbine

Describe typical examples of how mechanical systems will react when an emergency stop button is pressed

Delegates shall:

Engage in discussions about why it is important to prevent unexpected start-up

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THE PRINCIPLES OF BOLTED AND WELDED CONNECTIONS

80 min.

The aim of this lesson is to give Delegates an understanding of bolted and welded connections and its inspection.

To successfully complete this BTT Module, Delegates shall be able to:

Explain the principles of bolt connections (L2 – Knowledge).

Explain the location of important bolted and welded connections (L2 – Knowledge).

Explain how to visually inspect a welded connection (L2 – Knowledge).

Explain how to tighten and inspect bolt connections (L2 – Knowledge).

ELEMENT 4.1 - THE PRINCIPLES OF BOLT CONNECTIONS

Instructors shall:

Explain how to identify different types of bolts according to:

a. Dimensions

b. Threat type

c. Material and treatments (hot dip galvanized, electroplated, stainless steel, pre-lubricated…)

d. Quality

Explain how bolt strength is proportional to the size of the bolt and dependant of material, quality.

Explain the function of and types of washers

Explain the importance of bolt thread lubrication

Explain the importance of same temperature for all set components

Define and explain torque and tension

Explain the principles of angular tightening

Explain the importance of correct tightening (e.g. collapsing towers, electrical fires)

Delegates shall:

Engage in discussions about bolts, threads, lubricant, strengths of materials and temperature influences

Engage in discussions about force and torque

ELEMENT 4.2 - THE LOCATIONS OF IMPORTANT BOLTED AND WELDED CONNECTIONS

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Instructors shall:

Explain the connections between sections of the tower

Explain the platforms in the tower

Explain the ladders and guard rails inside and outside the tower

Show and explain an example of a bolted connection and a welded connection

Explain bolted connections holding cranes

Explain bolted connections with the Fall Arrester system

Explain bolted connections on the rotor, coupling, gearbox and generator

ELEMENT 4.3 - INSPECTION OF WELDED CONNECTIONS

Instructors shall :

Explain how to perform visual inspections of welded connections and document the findings (e.g.: paint damage, corrosion, cracks…)

ELEMENT 4.4 - BOLT CONNECTIONS AND CORRECT TIGHTENING TOOLS

Instructors shall:

Explain how to tighten a bolt connection (torque and tension) using Torque Wrench and Hydraulic tightening tools

Explain how to inspect if a bolt is loose (visual or with tightening tools)

Delegates shall :

Engage in discussions about the importance of inspection processes for bolted connections

USE OF MANUAL TIGHTENING AND MEASURING TOOLS

90 min.

The aim of this lesson is to give the Delegates the basic knowledge and practical skills to use manual tightening and measuring tools.

To successfully complete this BTT Module, Delegates shall be able to:

Identify the basic units for the metric system (L1 – Knowledge).

Demonstrate how to select and use the correct manual tightening tools (L3 – Skill).

Demonstrate how to set and use a torque wrench (L3 – Skill).

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Demonstrate how to use feeler gauges (L3 – Skill).

Demonstrate how to use a calliper (L3 – Skill).

Demonstrate how to use a dial gauge (L3 – Skill).

ELEMENT 5.1 - METRIC SYSTEM

Instructors shall:

Explain the key units used in the metric system for:

a. Temperature

b. Length

c. Weight

d. Speed

e. Torque

f.

Tension

g. Volume

h. Pressure

ELEMENT 5.2 - SELECTING AND USING THE CORRECT MANUAL TIGHTENING TOOLS

Instructors shall:

Explain the types of manual tightening tools (spanners, sockets, screwdrivers)

Explain the importance of and how to perform a pre-use check of tools

Demonstrate the correct application and size of manual tightening tool

Explain the consequences of incorrect manual tightening tool use

Demonstrate how to use an electrical impact gun (awareness of not surpassing bolt torque)

Delegates shall:

Practice and demonstrate the ability to select and use manual tightening tools

ELEMENT 5.3 - CORRECTLY SETTING AND USING A TORQUE WRENCH

Instructors shall:

Explain the function of a torque wrench

Explain the importance of pre-use check and calibration in terms of safety and quality

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Demonstrate how to set and use the torque wrench

Delegates shall:

Practice and demonstrate setting and using torque wrenches

ELEMENT 5.4 - FEELER GAUGES

Instructors shall:

Explain the function of feeler gauges

Explain the the importance of pre-use check in terms of safety and quality

Demonstrate how to use feeler gauges

Demonstrate how to care for feeler gauges to prevent damage

Delegates shall:

Practice and demonstrate the correct use and care of feeler gauges

ELEMENT 5.5 - CALLIPERS

Instructors shall:

Explain the function of callipers

Explain the importance of pre-use check in terms of safety and quality

Demonstrate how to use callipers

Demonstrate how to care for callipers to prevent damage

Delegates shall:

Practice and demonstrate the correct use and care of callipers (thicknesses, internal diameters and depth)

ELEMENT 5.6 - DIAL GAUGES

Instructors shall:

Explain the function of a dial gauge

Explain the importance of pre-use check in terms of safety and quality

Demonstrate how to use a dial gauge

Demonstrate how to care for Dial Gauges to prevent damage

Delegates shall:

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