GWO BTT v5


1 List of Abbreviations
5

2 Terms and Definitions
6

3 Change Log
7

4 Scope
10

5 General Requirements to GWO Training
11

5.1 Overview
11

5.2 Target Group
11

5.3 Aims and Objectives
11

5.4 Conformity with other Training
11

5.5 Legal Requirements
12

5.6 Duration of BTT Modules
12

5.7 Validity Period
13

5.8 Delegate Prerequisites for the BTT
14

5.9 Physical Demands
14

6 General Resources required to deliver BTT Modules
15

6.1 Instructors
15

6.2 Instructor/Delegate Ratio
15

6.3 Facilities and equipment
15

6.4 Theoretical Training Facilities
15

6.5 Practical Training Facilities
16

6.6 Equipment
16

6.7 Handouts
16

7 Understand GWO Learning Objectives
17

7.1 Taxonomy
17

8 Administration and Certification
19

8.1 Administrative Arrangements
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8.2 Delegate Performance Assessment
19

8.3 Control Measures
20

8.4 Requirement to upload training record in WINDA
20

8.5 Training Providers own Records and Certificates issue
21

9 Module 1 – The BTT Mechanical Module
22

9.1 Aims and objectives of the BTT Mechanical Module
22

9.2 Duration of the BTT Mechanical Module
22

9.3 Equipment
23

9.4 BTT Mechanical Module Time Table
23

9.5 Learning outcomes of the BTT Mechanical Module
25

Lesson 1 - Introduction
25

ELEMENT 1.1 - Safety instructions and emergency procedures
25

ELEMENT 1.2 - Facilities
25

ELEMENT 1.3 - Introduction
25

ELEMENT 1.4 - Aim and objectives
25

ELEMENT 1.5 - On-going assessments
26

ELEMENT 1.6 - Motivation
26

Lesson 2 - Mechanical Introduction
26

ELEMENT 2.1 - Main components of the structure
26

ELEMENT 2.2 - Main mechanical systems
26

ELEMENT 2.3 - How a turbine works
27

Lesson 3 - Mechanical Safety
27

ELEMENT 3.1 - Why Mechanical Safety
28

ELEMENT 3.2 - Safety Signs
28

ELEMENT 3.3 - Types of PPE
28

ELEMENT 3.4 - The importance of appropriate isolation
28

Lesson 4 - The principles of bolted and welded connections
29

ELEMENT 4.1 - The principles of bolt connections
29

ELEMENT 4.2 - The locations of important bolted and welded connections
30

ELEMENT 4.3 - Inspection of welded connections
30

ELEMENT 4.4 - Bolt connections and correct tightening tools
30

Lesson 5 - Use of manual tightening and measuring tools
30

ELEMENT 5.1 - Metric system
31

ELEMENT 5.2 - Selecting and using the correct manual tightening tools
31

ELEMENT 5.3 - Correctly setting and using a torque wrench
31

ELEMENT 5.4 - Feeler gauges
32

ELEMENT 5.5 - Callipers
32

ELEMENT 5.6 - Dial gauges
32

Lesson 6 - Hydraulic Torque and Tension
33

ELEMENT 6.1 - Using a hydraulic torque wrench
33

ELEMENT 6.2 - Using a hydraulic tensioning tool
33

Lesson 7 - Gearbox
34

ELEMENT 7.1 - The function and operating principles
34

ELEMENT 7.2 - Inspection of the gearbox
34

Lesson 8 - Braking system
34

ELEMENT 8.1 - The function of the mechanical and the aerodynamic brake
35

ELEMENT 8.2 - Inspection of the mechanical brake system
35

Lesson 9 - Yaw system
35

ELEMENT 9.1 - The function of the Yaw system
36

ELEMENT 9.2 - Inspection of the Yaw system
36

Lesson 10 - Cooling system
36

ELEMENT 10.1 - Components that require cooling and why
37

ELEMENT 10.2 - Inspection of the cooling systems
37

Lesson 11 - Lubrication system
37

ELEMENT 11.1 - Components requiring lubrication and why
38

ELEMENT 11.2 - Inspection of the lubrication systems
38

Lesson 12 - Summary and Theoretical test
39

ELEMENT 12.1 - Summary
39

ELEMENT 12.2 - Theoretical test
39

Lesson 13 - Evaluation
40

ELEMENT 13.1 - Evaluation
40

10 Module 2 - The BTT Electrical Module
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10.1 Aims and objectives of the BTT Electrical Module
41

10.2 Duration of the BTT Electrical Module
41

10.3 Equipment
42

10.4 BTT Electrical Module Time Table
42

10.5 Learning outcomes of the BTT Electrical Module
45

Lesson 1 - Introduction
45

ELEMENT 1.1 - Safety instructions and emergency procedures
45

ELEMENT 1.2 - Facilities
45

ELEMENT 1.3 - Introduction
45

ELEMENT 1.4 - Aim and objectives
45

ELEMENT 1.5 - On-going assessments
46

ELEMENT 1.6 - Motivation
46

Lesson 2 - Introduction to electricity
46

ELEMENT 2.1 - Direct current
46

ELEMENT 2.2 - Ohm’s Law
46

ELEMENT 2.3 - Alternating current
47

ELEMENT 2.4 - Alternating current/direct current
47

Lesson 3 - Electrical Safety
47

ELEMENT 3.1 - Why Electrical Safety
47

ELEMENT 3.2 - Low / High voltage
48

ELEMENT 3.3 - PE and GFCI/RCD
48

ELEMENT 3.4 - Stored energy
48

ELEMENT 3.5 - Static electricity
48

ELEMENT 3.6 - Safety signs
49

ELEMENT 3.7 - Types of PPE
49

ELEMENT 3.8 - The importance of appropriate isolation
49

Lesson 4 - Electrical Components
49

ELEMENT 4.1 - Resistors
50

ELEMENT 4.2 - Batteries
50

ELEMENT 4.3 - Switches
51

ELEMENT 4.4 - Contactors
51

ELEMENT 4.5 - Relays
51

ELEMENT 4.6 - Diodes
51

ELEMENT 4.7 - Bridge rectifiers
52

ELEMENT 4.8 - Capacitors
52

ELEMENT 4.9 - Transformers
52

ELEMENT 4.10 - Generators and motors
52

ELEMENT 4.11 - Fuses and circuit breakers
52

ELEMENT 4.12 - Processor Control Systems
53

Lesson 5 - Sensors
53

ELEMENT 5.1 - Introduction to sensors
53

ELEMENT 5.2 - Wind sensors
53

ELEMENT 5.3 - Temperature sensors
54

ELEMENT 5.4 - Position sensors
54

ELEMENT 5.5 - Other sensors
54

Lesson 6 - Electrical circuits
54

ELEMENT 6.1 - Symbols and diagrams
55

ELEMENT 6.2 - Assembly of an electrical circuit
55

Lesson 7 - Electrical measuring instruments
55

ELEMENT 7.1 - Symbols and settings on Electrical Measuring Instruments
56

ELEMENT 7.2 - How to measure with Electrical Measuring Instruments
56

ELEMENT 7.3 - Measuring points
56

Lesson 8 - Summary and Theoretical test
57

ELEMENT 8.1 - Summary
57

ELEMENT 8.2 - Theoretical test
57

Lesson 9 - Evaluation
57

ELEMENT 9.1 - Evaluation
57

11 Module 3 - The BTT Hydraulic Module
59

11.1 Aims and objectives of the BTT Hydraulic Module
59

11.2 Duration of the BTT Hydraulic Module
59

11.3 Equipment
60

11.4 BTT Hydraulic Module Time Table
60

11.5 Learning outcomes of the BTT Hydraulic Module
62

Lesson 1 - Introduction
62

ELEMENT 1.1 - Safety instructions and emergency procedures
62

ELEMENT 1.2 - Facilities
62

ELEMENT 1.3 - Introduction
62

ELEMENT 1.4 - Aim and objectives
62

ELEMENT 1.5 - On-going assessments
63

ELEMENT 1.6 - Motivation
63

Lesson 2 - Hydraulic Introduction
63

ELEMENT 2.1 - The hydraulic system
63

ELEMENT 2.2 - Pascal’s law
63

Lesson 3 - Hydraulic Safety
64

ELEMENT 3.1 - Why Hydraulic Safety
64

ELEMENT 3.2 - High pressure systems
64

ELEMENT 3.3 - Stored Energy
65

ELEMENT 3.4 - Safety signs
65

ELEMENT 3.5 - Chemicals
65

ELEMENT 3.6 - Types of PPE
65

ELEMENT 3.7 - The importance of appropriate isolation
66

Lesson 4 - Pumps
66

ELEMENT 4.1 - Introduction to pumps
66

ELEMENT 4.2 - Pumps exercise
67

Lesson 5 - Actuator
67

ELEMENT 5.1 - Introduction to actuators
67

Lesson 6 - Valves
67

ELEMENT 6.1 - Introduction to Valves
68

ELEMENT 6.2 - Directional Control Valves
68

ELEMENT 6.3 - Pressure relief valves
69

ELEMENT 6.4 - Pressure reduction valves
69

ELEMENT 6.5 - Needle valves
69

ELEMENT 6.6 - Non-return valves
69

ELEMENT 6.7 - Throttle valves
70

ELEMENT 6.8 - Restrictor valves
70

Lesson 7 - Accumulators
70

ELEMENT 7.1 - Introduction to accumulators
71

ELEMENT 7.2 - Pre-charge pressure
71

Lesson 8 - Sensors
71

ELEMENT 8.1 - Introduction to sensors
71

ELEMENT 8.2 - Pressure sensors
72

Lesson 9 - Pipes, hoses and connections
72

ELEMENT 9.1 - Oil Transfer
72

ELEMENT 9.2 - Hydraulic connections
72

Lesson 10 - Oil and filters
73

ELEMENT 10.1 - Handling oil procedures/cleanliness
73

ELEMENT 10.2 - Collecting an oil sample
73

ELEMENT 10.3 - Checking oil level
73

ELEMENT 10.4 - Filters
74

Lesson 11 - Hydraulic diagrams
74

ELEMENT 11.1 - Symbols and diagrams
74

ELEMENT 11.2 - Identifying measuring points
75

Lesson 12 - Pressure measuring tools
75

ELEMENT 12.1 - Pressure gauge/manometer
75

ELEMENT 12.2 - Pressure measuring
76

Lesson 13 - Summary and Theoretical test
76

ELEMENT 13.1 - Summary
76

ELEMENT 13.2 - Theoretical test
76

Lesson 14 - Evaluation
77

ELEMENT 14.1 - Evaluation
77

12 Module 4 - The BTT Installation Module
78

12.1 Aims and objectives of the BTT Installation Module
78

12.2 Duration of the BTT Installation Module
78

12.3 Delegate Prerequisites for the BTT Installation Module
79

12.4 Equipment
79

12.5 BTT Installation Module Time Table
79

12.6 Learning outcomes of the BTT Installation Module
82

Lesson 1 - Introduction
82

ELEMENT 1.1 - Safety instructions and emergency procedures
82

ELEMENT 1.2 - Facilities
82

ELEMENT 1.3 - Introduction
82

ELEMENT 1.4 - Aim and objectives
82

ELEMENT 1.5 - On-going assessments
83

ELEMENT 1.6 - Motivation
83

Lesson 2 - Introduction to Installation
83

ELEMENT 2.1 - Installation Overview
83

ELEMENT 2.2 - Why Installation Safety
84

ELEMENT 2.3 - Safety Signs
85

ELEMENT 2.4 - ELEMENT 2.4 Types of PPE
85

ELEMENT 2.5 - ELEMENT 2.5 The importance of appropriate isolation
85

Lesson 3 - General procedures for working onsite with installation
85

ELEMENT 3.1 - Checklists, Work Instructions, etc.
86

ELEMENT 3.2 - Housekeeping
86

Lesson 4 - Installation environments
86

ELEMENT 4.1 - Installation environments
87

Lesson 5 - Handling and storing
87

ELEMENT 5.1 - Risks and hazards associated with handling and storing
88

ELEMENT 5.2 - Reception / Inspection
88

ELEMENT 5.3 - Unload and storage of blades, nacelle, tower sections & hub
89

ELEMENT 5.4 - Tools and equipment
89

ELEMENT 5.5 - Return goods and components
89

Lesson 6 - Lifting operations
90

ELEMENT 6.1 - Types of lifting
90

ELEMENT 6.2 - Risks and hazards associated with lifting operations
91

ELEMENT 6.3 - Roles and responsibilities
91

Lesson 7 - Main components preparation, pre-assembly and assembly
92

ELEMENT 7.1 - Preparation, pre-assembly and assembly
92

ELEMENT 7.2 - Risks and hazards associated with main component preparation, pre-assembly and assembly
93

ELEMENT 7.3 - Challenges when assembling main components
93

Lesson 8 - Principles of Mechanical Completion
94

ELEMENT 8.1 - Introduction to mechanical completion
94

ELEMENT 8.2 - Examples of mechanical completion
94

ELEMENT 8.3 - Risks and hazards associated with mechanical completion
94

Lesson 9 - Principles of electrical completion including cable work
95

ELEMENT 9.1 - Introduction to electrical completion
95

ELEMENT 9.2 - Examples of electrical completion
96

ELEMENT 9.3 - Risks and hazards associated with handling and working with cables
96

ELEMENT 9.4 - Different types of cables
96

ELEMENT 9.5 - Simple installation diagrams
97

ELEMENT 9.6 - Cutting and crimping of cables
97

ELEMENT 9.7 - Marking, routing and termination of all cable types
98

Lesson 10 - Principles of hydraulic completion
100

ELEMENT 10.1 - Introduction to hydraulic completion
100

ELEMENT 10.2 - Examples of hydraulic completion
100

ELEMENT 10.3 - Risks and hazards associated with hydraulic completion
101

Lesson 11 - Principles of operation with external generator
101

ELEMENT 11.1 - Principles of yaw, rotor and blades operation without grid-power
102

ELEMENT 11.2 - Risks and hazards associated with operation of auxiliary systems with external generator
102

ELEMENT 11.3 - Preconditions for operation of lift with external generator
102

ELEMENT 11.4 - Preconditions for operation of internal crane with external generator
103

ELEMENT 11.5 - Use of external generators for other auxiliary uses
103

Lesson 12 - Introduction to handover to commissioning
104

ELEMENT 12.1 - Handover to commissioning
104

ELEMENT 12.2 - Risks and hazards associated with handing over to commissioning
104

Lesson 13 - Summary and Theoretical test
105

ELEMENT 13.1 - Summary
105

ELEMENT 13.2 - Theoretical test
105

Lesson 14 - Evaluation
105

ELEMENT 14.1 - Evaluation
106
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