Technical training
Blade Repair Training Standard
V6
Publication date: 10032026
Technical training
Blade Repair Standard / V5 23022026
CONTENTS
1. LIST OF ABBREVIATIONS .................................................................................................................................4
2. TERMS AND DEFINITIONS...............................................................................................................................4
3. CHANGE LOG ................................................................................................................................................... 5
4. SCOPE .............................................................................................................................................................10
5. GENERAL REQUIREMENTS FOR THE GWO BLADE REPAIR........................................................................10
5.1 5.2 5.3 5.4 5.5
Target Group
10 10 11 11 11
Aims and Objectives
Validity Period Course Codes
Participant Prerequisites for the Blade Repair Module
6. GENERAL RESOURCES REQUIRED TO DELIVER BLADE REPAIR MODULE ................................................11
6.1 6.2 6.3
Instructors
11 12 13
Practical Training Facilities
Training Equipment
7. USING THIS STANDARD TO DEVELOP TRAINING .......................................................................................13
7.1
Adherence to legislative requirements on chemical substances
13
8. ADMINISTRATION AND CERTIFICATION OF MODULE ..............................................................................13
8.1
Participant Performance Assessment
13
9. BLADE REPAIR MODULE................................................................................................................................17
9.1 9.2 9.3 9.4 9.5
Aims and Objectives of the Blade Repair Module
17 18 18 18 24
Duration
Blade Repair Module Participant Ratio Blade Repair Module Timetable
Detailed Description of the Blade Repair Module
Introduction to the training .............................................................................................................. 24 Blade repair and legislative framework on chemical substances......................................................29 Safety data sheets ............................................................................................................................ 31 Work instruction ............................................................................................................................... 34 Risk assessments............................................................................................................................... 35 Secure an area .................................................................................................................................. 37 Contamination .................................................................................................................................. 38 Waste segregation ........................................................................................................................... 41
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Ergonomics....................................................................................................................................... 42 Lock out tag out (LOTO)................................................................................................................. 44 Personal protective equipment ...................................................................................................... 45 Masks and filters ............................................................................................................................. 49 Chemical safety .............................................................................................................................. 53 Composites and blade construction............................................................................................... 57 Materials ......................................................................................................................................... 62 Tools and equipment ..................................................................................................................... 68 Phase test ....................................................................................................................................... 76 Lamination skills.............................................................................................................................. 76 Basic lamination.............................................................................................................................. 87 Sandwich panel .............................................................................................................................. 90 Painting........................................................................................................................................... 98 Blade inspection ........................................................................................................................... 100 Inspection lightning protection system ........................................................................................ 106 Sanding skills ................................................................................................................................ 109 Grinding skills ............................................................................................................................... 112 Surface repairs .............................................................................................................................. 114 Laminate repairs ........................................................................................................................... 120 Filling, shaping and finishing ........................................................................................................ 131 Trailing edge repairs..................................................................................................................... 132 Leading edge repairs.................................................................................................................... 136 Sandwich panel repair .................................................................................................................. 140 Bond line repairs .......................................................................................................................... 144 Summary and final test ................................................................................................................. 148 Training review ............................................................................................................................. 149
ANNEX 1 - EQUIPMENT LIST ....................................................................................................................................152
ANNEX 2 - PRACTICAL EXERCISE (EXAMPLE) .........................................................................................................156
ANNEX 3 - WORK INSTRUCTION 1 (EXAMPLE) .......................................................................................................160
ANNEX 4 - WORK INSTRUCTION 2 (EXAMPLE) .......................................................................................................168
ANNEX 5 - PHOTOCARD ..........................................................................................................................................181
ANNEX 6 - VERSION HISTORY ..................................................................................................................................182
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1. LIST OF ABBREVIATIONS
Biax
Biaxial
CS
Chopped Strand
GWO
Global Wind Organisation
LOTO
Lock Out Tag Out
PPE
Personal Protective Equipment
SDS
Safety Data Sheet
TDS
Technical Data Sheet
TG
Glass Transition
Triax
Triaxial
UD
Unidirectional
WI
Work Instructions
WINDA
GWO training record database
2. TERMS AND DEFINITIONS
Term
Definition
A thin, pre-cured sheet of fibre reinforced composite material. Usually consisting of 1 layer of 600 gsm biax glass fibre.
Hardback
For clarity where the word ‘must’ is used in this standard it shall have the same meaning as ‘shall’.
Must
Verbal form used to indicate requirements strictly to be followed in order to conform to this training standard and from which no deviation is permitted.
Shall
Verbal form used to indicate that among several possibilities one is recommended as particularly suitable, without mentioning or excluding others, or that a certain course of action is preferred but not necessarily required.
Should
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3. CHANGE LOG
Publication date
Version
10032026
6
For detailed descriptions of changes, please see the changelog published on GWO’s website here:
Blade Repair V6 Change Log. Changes throughout:
• Corrected spelling mistakes, abbreviations and taxonomy inconsistencies
• New lesson incorporated as Lesson 2 adds one number to all subsequent module lessons. Learning objectives and activities are renumbered accordingly. All changelog entries refer to new numbering of Blade Repair V6, except when Blade Repair V5 is specifically mentioned • Waste Segregation as defined in Lesson 8 must be performed as part of practical exercises throughout lesson 19-21 and 24-32
• Incorporation of safety data sheets throughout practical exercises
• Timing has been adjusted for some lessons. Overall Blade Repair Module duration remains identical
Blade Repair Module
Section 7.1. New section on legislative requirements:
• Clarification on adherence to legislation in different supranational regions
Section 8.1. New note on the phase test:
Clarification on aim of phase test
•
Lesson 2 (New Lesson)
• New lesson on Blade Repair and Legislative Framework of Chemical Substances
• Blade Repair activities are aligned with core objectives and key principles of relevant supranational legislation
Lesson 3 (Lesson 2 in Blade Repair V5)
• 5 minutes added for granular understanding of how to obtain safety information
• Element 3.1, Learning objective 17 text revised to ensure covering of legal obligations in relation to adherence supranational legislation
• Elements 3.2.1, 2, 4 and 5 are expanded for elaborate understanding of safety information obtaining
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• Element 3.4.2 and 4 + Learning Objective 23 revised to emphasise importance of hazard label understanding
• V5 Element 2.5 on Personal Protective Equipment moved to Lesson 11 and merged with Element 11.1
Lesson 4 (Lesson 3 in Blade Repair V5)
• 10 minutes added for granular understanding of work instruction application
• New element 4.1.1 related to purpose and significance of work instruction
Lesson 5 (Lesson 4 in Blade Repair V5)
• 10 minutes added to lesson for granular understanding of work instruction application
• V5 Element 4.1 and 4.2 merged – All activities remain
• Element 5.1.1, 2 and 4C revised to emphasize legal purpose and aspects of risk assessments
Lesson 8 (Lesson 7 in Blade Repair V5)
• 5 minutes added to lesson for extra emphasis of legal and practical implications of waste segregation
• Element 8.1.3 added to for understanding of the difference between dust and chemicals
• Element 8.2 Learning Objective 56 revised to emphasize importance of applying information from safety data sheets
Lesson 11 (Lesson 10 in Blade Repair V5)
• Lesson aim is linked to information obtained in safety data sheets.
• Element 2.5 from Blade Repair V5 is merged with Element 11.1
• Element 11.1.4 and 7 revised to emphasise connection to hierarchy of control and practical exercises
• Masks and filters removed from Element 11.2.1 (covered in next Lesson 12)
• Element 11.4.5 and Learning Objective 76 revised to ensure compliance with safety data sheet and relevant legislation
Lesson 12 (Lesson 11 in Blade Repair V5)
• Lesson Aim and Element 12.2.1 and 12.2.4 revised to ensure compliance with safety data sheets
• Element 12.4.1 and 12.4.2 revised to emphasise details on mask application
Lesson 13 (Lesson 12 in Blade Repair V5)
• Successive order of Element 12.1,2,3,4 and 5 from Blade Repair V5 is revised for Blade Repair V6 element 13.1,2,3,4 and 5 • Element 13.2.1, 2 and 4, Element 13.4.1 and Learning Objective 90 revised to emphasise application of safety data sheet in the context of chemical safety.
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Lesson 15 (Lesson 14 in Blade Repair V5)
• Note added to emphasise importance of applying PPE when handing materials
• Element 15.5.1, 2 and 5 revised to emphasise importance of applying technical data sheets and safety data sheets when handling chemicals
Lesson 18 (Lesson 17 in Blade Repair V5)
• Note added to emphasise importance of applying PPE when handing materials
• Note added to emphasise that Lesson 18 is a theoretical prerequisite for Lesson 19
• Note added to Element 18.1 recommending a physical sample display of cutout square glass fibre
• Blade Repair V6 Element 18.2 on fibreglass mats is moved from Blade Repair V5 Lesson 18 on basic lamination
Lesson 19 (Lesson 18 in Blade Repair V5)
• Note added to emphasise importance of waste segregation
• Note added to emphasise importance of referring to safety data sheets and technical data sheets
• Element on fibreglass moved to previous lesson
• Element 19.1.3 revised to highlight adherence to safety data sheets, work instruction and applicable legislation
Lesson 20 (Lesson 19 in Blade Repair V5)
• Note added to emphasise importance of waste segregation
• Note added to emphasise importance of referring to safety data sheets and technical data sheets
• Element 20.4.19 added to emphasise importance of hardness measuring
Lesson 21 (Lesson 20 in Blade Repair V5)
• Note added to emphasise importance of waste segregation
• Note added to emphasise importance of referring to safety data sheets and technical data sheets
• Element 21.1.1 e. and f. + 21.1.7 and 9 added to highlight correct application of one-, and two-factor component paint
Lesson 22 (Lesson 21 in Blade Repair V5)
• Lesson 22 has been reduced by 30 minutes to 200 minutes
• Element 22.7.7 revised to highlight importance of reporting defects in blade
Lesson 23 (Lesson 22 in Blade Repair V5)
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15 minutes has been added to Lesson 23
•
• Element 23.3.7 and 10 has been added for demonstration of receptor replacement
Lesson 24 (Lesson 23 in Blade Repair V5)
• Note added to emphasise importance of waste segregation
• Note added to emphasise importance of referring to safety data sheets and technical data sheets
• Element 24.1.1 has been revised to highlight hand-arm vibration syndrome as a hazard
• Learning Objective 212 revised to ensure consistency with GWO taxonomy
Lesson 25 (Lesson 24 in Blade Repair V5)
• Note added to emphasise importance of waste segregation
• Note added to emphasise importance of referring to safety data sheets and technical data sheets
• Element 25.1.1 has been revised to highlight hand-arm vibration syndrome as a hazard
• Learning Objective 218 revised to ensure consistency with GWO taxonomy
Lesson 26 (Lesson 25 in Blade Repair V5)
• Note added to emphasise importance of waste segregation
• Note added to emphasise importance of referring to safety data sheets and technical data sheets
• Learning Objective 228 and corresponding activities is moved to Element 26.3 from Lesson 28 on filling, shaping and finishing
• Element 26.6.1 and 3 is revised to highlight application of two-factor component paint.
Lesson 27 (Lesson 26 in Blade Repair V5)
• Lesson 27 has been reduced by 25 minutes to 575 minutes
• Note added to emphasise importance of waste segregation
• Note added to emphasise importance of referring to safety data sheets and technical data sheets
Lesson 28 (Lesson 27 in Blade Repair V5)
• Note added to emphasise importance of waste segregation
• Note added to emphasise importance of referring to safety data sheets and technical data sheets
• Learning Objective 266 and corresponding activities from Blade Repair V5 has been moved to Element 26.3 for better flow
• Learning Objective 270 revised to ensure coherence with activities in the previous Lesson
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Lesson 29 (Lesson 28 in Blade Repair V5)
• Note added to emphasise importance of waste segregation
• Note added to emphasise importance of referring to safety data sheets and technical data sheets
• Element 29.3.5 and 8 revised to emphasise importance of hardness measuring
• Element 29.4.3 and 5 revised to ensure application of knowledge from Lesson 21
Lesson 30 (Lesson 29 in Blade Repair V5)
• Note added to emphasise importance of waste segregation
• Note added to emphasise importance of referring to safety data sheets and technical data sheets
• Element 30.3.2 and 4 revised to emphasise importance of hardness measuring
• Element 30.4.2 and 4 revised to ensure application of knowledge from Lesson 21
Lesson 31 (Lesson 30 in Blade Repair V5)
• Note added to emphasise importance of waste segregation
• Note added to emphasise importance of referring to safety data sheets and technical data sheets
Lesson 32 (Lesson 31 in Blade Repair V5)
• Note added to emphasise importance of waste segregation
• Note added to emphasise importance of referring to safety data sheets and technical data sheets
• Element 32.3.2 and 5 revised to ensure application of knowledge from Lesson 21
• Element 32.3.3 has been revised to highlight importance of photo documentation
Annex 1 – Equipment List.
• Equipment list requirements revised and aligned with GWO Requirements for Training
• Two-factor component paint has been added to list of mandatory consumable materials
Annex 4 – Work Instruction 2 (Example
• Extra work instruction template example for practical application added
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4. SCOPE
Global Wind Organisation is a non-profit body founded by the wind turbine manufacturers and owners. Our members strive for an injury free work environment in the wind turbine industry, setting common international standards for safety training and emergency procedures.
This standard describes the requirements for Blade Repair training that are recommended by the members of GWO. The standard comprises of one module.
GWO recognises trained persons as competent within blade repair in the wind industry. GWO accepts the trained person as possessing the required knowledge, skills, and abilities to stop an unsafe work situation where they, as duty holders, are accountable for safety. This standard has been developed in response to the demand for recognisable Blade Repair training in the industry and has been prepared in co-operation between the members of GWO based on risk assessments, in-depth descriptions of job roles and tasks relevant to blade repair in the wind industry as well as factual incident and accident statistics from G+ and the wind industry.
Training is verified through GWO’s WINDA database.
General feedback on this document can be sent to info@globalwindsafety.org See globalwindsafety.org on how to raise a complaint about a training provider or report a safety incident occurring during training.
5. GENERAL REQUIREMENTS FOR THE GWO BLADE REPAIR Upon completion of the GWO Blade Repair Standard (BR), participants 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 Standard training 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) that are defined as functions where composite work training, according to this standard, may mitigate some of the identified hazards and risks. 5.2 Aims and Objectives Training in accordance with this standard will enable participants 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 Standard training course, participants will be able to work safely with composite materials while conducting inspection and basic blade repair procedures, thereby
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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 Validity Period The Blade Repair Module training is an enduring qualification and therefore a validity period does not apply to this training. This assumes that the participants are actively working with composite inspection and repair.
5.4 Course Codes
Module
Course Code
Blade Repair
BR
Table 5.4.1 – GWO Blade Repair Module course code
5.5 Participant Prerequisites for the Blade Repair Module All personnel participating in Blade Repair Module training shall be medically fit and capable of fully participating. Specifically, the participants must be made aware of the risks and hazards related to completing this course while being allergic to the materials used in the module. This also applies for participants suffering from asthma and hyperhidrosis manuum (excessive hand sweating).
In addition to the above, all personnel participating must meet the participant prerequisites described in the GWO Requirements for Training.
6. GENERAL RESOURCES REQUIRED TO DELIVER BLADE REPAIR MODULE
The training provider shall ensure that the instructors, facilities, and equipment are in place to support the training of the participants.
6.1 Instructors The instructor shall possess appropriate qualifications and experience to ensure that all training and supportive activities are carried out in accordance with current legislation and the requirements outlined in GWO’s Requirement for Training document. In addition to these requirements instructors for this training standard shall have the following:
The instructor must:
1. Hold valid training records for GWO BST/BSTR First Aid and GWO BST/BSTR Manual Handling
2. Be able to demonstrate knowledge and practical skills in blade repair methods, techniques, and craftsmanship comparable to those executed by the participants during the practical exercises of the Blade Repair Module
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3.
Act as first responder in the case of an accident
Supporting staff:
1. A person with a valid first aid qualification shall be present during all practical training. This can be the instructor or an assigned emergency response team
6.2 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.
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 participants’ 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 elements comparable to a real wind turbine working environment as is reasonably practicable. The practical training facility should enable each participant to, individually and/or as part of a team, see, hear and practise 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 with sufficient:
1. dust extraction to ensure that the amount of dust in the air is kept below 10 milligrams per cubic metre
2.
filtration of extracted air to prevent environmental contamination
3. exposure control measures to limit exposure limits for the instructor and participants to those as stated in the safety data sheet for all materials being used
4. 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
5. segregation from classrooms and administrative areas to prevent cross contamination of chemicals
6.
waste segregation to prevent cross contamination
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 participants and staff can change their shoes to prevent contamination of clean areas with chemicals.
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The above are the minimum requirements, if national legislation and regulations supersede this, then they must be followed.
6.3 Training Equipment
The equipment required for training as listed in Annex 1 must be available and must fulfil national legal requirements in the country where the training is taking place.
7. USING THIS STANDARD TO DEVELOP TRAINING The training in this standard is designed around the GWO taxonomy described in the GWO Requirements for Training. Theoretical and practical activities must be delivered according to the defined taxonomic level in order to reach the described learning objectives. When teaching equipment, a generic approach shall be applied aiming to avoid additional potential product specific formal training after completion of this training. However, national legislation, company gap analysis and location specific risk assessments may require additional product specific familiarisation which is the responsibility of the duty holder.
In addition to this, all training based on this standard including all related resources shall, as a minimum, meet the requirements described in the GWO Requirements for Training.
7.1 Adherence to legislative requirements on chemical substances
Annex 1 of the Blade Repair Standard specifies several consumable materials which are regulated by national and supranational chemical substance legislation. The training provider must include these legal requirements in the training so that course participants are able to carry out their duties globally. This including the following supranational regions:
•
EU countries
•
United States & Canada
•
Australia
•
China
8. ADMINISTRATION AND CERTIFICATION OF MODULE
8.1 Participant Performance Assessment Participants will be assessed by means of direct observation and supplementary oral questions where appropriate (formative evaluation). The participants will also be subjected to written phase tests after theory elements, and again after the close of the training course (summative evaluation).
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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:
1. there shall be an instructor present in the room where written tests are being conducted for the entire duration of the written test
2.
the participants shall not communicate with each other during the test
3. the participants shall not communicate with any persons via email, telephone, Skype (or similar) or social media during the test
4. the participants shall be allowed to use training material, handouts, and their own notes during the test
5. where a participant does not understand the meaning of a question or a multiple-choice option, the instructor shall be allowed to help the participant to understand the meaning of the question or the multiple-choice options. The instructor shall not give the participants the correct answers to any test questions
6.
there shall be a time limit of 1½ minutes per question
7. the written test questions cannot be used during the training in such a way that the participants could recognise that they will be test questions
8. each participant must answer at least 70% of written test questions correctly to pass the test
If a participant does not reach the passing criteria in written or observational tests, the instructor shall discuss this with the participant to find out the reason. If this 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 participants 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 participants not meeting the stated learning objectives.
Throughout the entire GWO blade repair course, the instructor will use the participant assessment form (see Requirements for Training) to evaluate the participants’ knowledge and skills, with a high focus on evaluating the participants’ safety awareness and craftsmanship skills.
The instructor shall keep a participant assessment form (or adaptation) for each participant until the completion / evaluation of the Blade Repair Module Training.
The participant assessment form (or adaptation) is a final evaluation tool for the instructors to assess participants during practical elements. It allows measurement of the number of violations regarding safety, competency or ability.
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The participant assessment form shall be used as a progressive evaluation tool to discuss the performance of a participant to guide them to success. It also serves as supporting documentation if a participant passes or fails the module. If a participant fails to meet the demands of the Blade Repair Module training, 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 participant left the course or where the instructor deems constructive.
Training providers may adapt the participant assessment form to other media. Training providers must have a documented procedure in place for dealing with participants not meeting the stated learning outcomes.
It is not possible to fail the phase test (Lesson 17). The instructor can use the participation assessment form as an evaluation tool and provide constructive feedback, if the phase test reveals that the participant hasn’t reached the learning objectives.
Note
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Blade Repair Module
(BR)
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9. BLADE REPAIR MODULE
9.1 Aims and Objectives of the Blade Repair Module The aim of this module is to enable participants, through theoretical and practical training, to support and care for themselves and others working in the wind industry by possessing the necessary knowledge, skills, and ability for blade repair. Upon successful completion of the Blade Repair Module training, the participants will be able to perform and document a wind turbine blade inspection, and 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:
1. laminate repairs including leading edge and trailing edge repairs affecting a maximum amount of five layers and a maximum repair area size of 500cm²
2.
core material replacement up to 200cm²
3.
surface repair to paint and gelcoat
The GWO Blade Repair Module training is intended as an entry level course, and the participants will not therefore be expected to perform repairs in major structural elements of blades like spars, spar caps and carbon fibre.
After having successfully completed this GWO Blade Repair Module, the participants will have the ability to:
1) Take responsibility for working safely with applicable chemicals, while utilising the applicable personal protective equipment in a controlled manner throughout all phases of blade inspection and repair work (Ability, intermediate level)
2) Explain typical types of blade construction, materials and the importance of surface finish relating to aerodynamic performance and efficiency (Knowledge, intermediate level)
3) 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 (Skills, intermediate level)
4) Take responsibility for preparing, operating, and maintaining the correct tools and equipment, be it electrical or mechanical (Ability, intermediate level)
5) Take responsibility for safely performing and documenting laminate, sandwich panel and surface layer repairs in accordance with a work instruction in glass fibre reinforced composite parts (Ability, intermediate level)
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9.2 Duration
The total contact time for completing the Blade Repair Module is estimated to be 70 hours and 20 minutes.
The training provider must not exceed the time per day given in the table 9.2.1 below.
Maximum Duration Per Day
Contact time
8 hours
Total training day
10 hours
Table 9.2.1 – Maximum duration for training day
Contact time includes delivery of course lesson content, practical exercises and activities directly related to these.
Note
The total training day includes contact time, meals and breaks and travel between training sites (where applicable).
9.3 Blade Repair Module Participant Ratio
The ratio shown for theory sessions indicates the maximum number of participants per instructor attending the course.
Practical ratios indicate the maximum number of participants to be supervised by an instructor during each activity.
Module
Session
Instructor to Participant Ratio
Theory
1:12
Blade Repair
Practical
1:6
Table 9.3.1 – Instructor to participant ratio
9.4 Blade Repair Module Timetable
The order in which elements of this module training are delivered may vary according to the didactical choices of the delivering training provider.
The delivery of this module must comply with the requirements described in the GWO Requirements for Training .
Lesson
Element
Duration
1. Introduction to the training
1.1
Safety instructions and emergency procedures
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1.2
Facilities
1.3
Introduction
1.4
Scope and main learning objectives
Ongoing assessment (participant assessment form)
1.5
1.6
Motivation
1.7
Human factors TOTAL
20 min.
2. Blade Repair and legislative framework on chemical substances
2.1
Legislative concepts
2.2
Downstream users
TOTAL
20 min.
3. Safety data sheets
3.1
Safety data sheets
3.2
Safety data sheet location
3.3
Safety instructions
3.4
Hazard labels and symbols TOTAL
20 min.
4. Work instruction
4.1
The work instruction (WI)
4.2
Locate work instruction TOTAL
20 min.
5. Risk assessments
5.1
Risk assessments TOTAL
20 min.
6. Secure an area
6.1
Locate procedures
6.2
Securing the area TOTAL
10 min.
7. Contamination
7.1
Characteristics
7.2
Work instructions as mitigation
7.3
Avoiding contamination TOTAL
15 min.
8. Waste segregation
8.1
Correct waste segregation
8.2
Waste segregation information TOTAL
15 min.
9. Ergonomics
9.1
Classroom
9.2
Workshop
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9.3
Bladework TOTAL
15 min.
10. Lock Out Tag Out (LOTO)
10.1 Lock Out Tag Out TOTAL 11.1 Types & Purpose 11.2 Application 11.3 Limitations 11.4 Task specific 11.5 Disposal TOTAL
10 min.
11. Personal protective equipment
100 min.
12. Masks and filters
12.1 Purpose 12.2 Filter categories 12.3 Categories and lifetime 12.4 Masks 12.5 Apply filters TOTAL 13.1 Purpose 13.2 Information about chemicals 13.3 Equipment check 13.4 Prevention and mitigation 13.5 Transfer procedures TOTAL 14.1 Aerodynamics 14.2 Blade construction 14.3 Sandwich panel 14.4 Blade enhancements 14.5 Faults, implications and mitigations TOTAL 15.1 Reinforcement materials 15.2 Matrix materials 15.3 Adhesives 15.4 Surface coatings 15.5 Chemical handling and application 15.6 Curing
45 min.
13. Chemical safety
90 min.
14. Composites and blade construction
60 min.
15. Materials
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TOTAL
75 min.
16. Tools and equipment
16.1 Mechanical, electrical and pneumatic principles 16.2 Utilisation of tools and materials 16.3 Calibration 16.4 Lamination tools 16.5 Heating blankets 16.6 Checking electrical tools and equipment 16.7 Vibrating tools
16.8 Electrical safety devices 16.9 Documentation types TOTAL
40 min.
17. Phase test
17.1 Phase test TOTAL
30 min.
18. Lamination skills
18.1 Fibre orientation 18.2 Fibreglass mats 18.3 Kinked or bent fibres 18.4 Overlaps 18.5 Dry fibres and air voids 18.6 Mixing ratio
18.7 Calculation of matrix material 18.8 Curing at elevated temperatures 18.9 Ascertaining correct curing 18.10 Ambient temperature and humidity 18.11 Recording ambient temperature and humidity TOTAL 19.1 Minimise risks associated with fibre work 19.2 Fibre orientation and moulding theory TOTAL 20.1 Minimise risks associated with composite fibre work 20.2 Sandwich construction 20.3 Curing of fibre reinforced composite laminate 20.4 Producing a composite sandwich panel 20.5 Trailing edge section
150 min.
19. Basic lamination
290 min.
20. Sandwich panel
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TOTAL
420 min.
21. Painting
21.1 Completion of blade TOTAL
120 min.
22. Blade inspection
22.1 Typical failures 22.2 Reactions to damage categories 22.3 Focused and scaled photographs 22.4 Tap test 22.5 Lighting 22.6 Inspection tools and methods 22.7 Types of damage TOTAL 23.1 Surface components 23.2 Visual conductivity inspection 23.3 Measure resistance TOTAL
200 min.
23. Inspecting lightning protection system
65 min.
24. Sanding skills
24.1 Sanding TOTAL 25.1 Grinding TOTAL
55 min.
25. Grinding skills
110 min.
26. Surface repairs
26.1 Minimise risks associated with composite fibre work 26.2 Filler adhesion 26.3 Reproduce surface profile 26.4 Paint adhesion 26.5 Layer thickness 26.6 Apply paint with a roller 26.7 Layer thickness with wet film 26.8 Record ambient temperature and humidity 26.9 Inspection and documentation TOTAL 27.1 Minimise risks associated with composite fibre work 27.2 Safe removal of damaged material 27.3 Identifying fibre direction
180 min.
27. Laminate repairs
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27.4 Reinforcement overlaps and matrix adhesion 27.5 Mixing 27.6 Repair layers 27.7 Wetting out fibres using appropriate tools 27.8 Wetting out fibres with matrix material 27.9 Vacuum consolidation 27.10 Curing the repair using heating blankets 27.11 Verifying the curing 27.12 Recording the ambient temperature and humidity TOTAL
575 min.
28. Filling and shaping
28.1 Filler
TOTAL
180 min.
29. Trailing edge repairs
29.1 Minimise the risks associated with composite fibre work 29.2 Repair task 29.3 Crack repairs 29.4 Recreating blade profile 29.5 Record ambient temperature and humidity TOTAL 30.1 Minimise risks associated with composite fibre work 30.2 Repair task
380 min.
30. Leading edge repairs
30.3 Leading edge repair 30.4 Relocate leading edge TOTAL
440 min.
31. Sandwich panel repair
31.1 Minimise risks associated with composite fibre work 31.2 Repair task 31.3 Repair inner and outer laminate 31.4 Replacement core 31.5 Inspection and documentation TOTAL
180 min.
32. Bond line repairs
32.1 Debonding 32.2 Injection of adhesive
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32.3 Injecting material in the trailing edge TOTAL
180 min.
33. Summary and final test
33.1 Summary 33.2 Final test TOTAL
60 min.
34. Training review
34.1 Training review 34.2 Feedback session TOTAL
30 min.
GRAND TOTAL
4220 min.
9.5 Detailed Description of the Blade Repair Module INTRODUCTION TO THE TRAINING
20 min.
The aim of this lesson is for the participants to be motivated and to engage in the training safely at a training facility, while recognising what is expected of them during the training.
After having successfully completed lesson 1 of the Blade Repair Module, the participants can:
1) Recognise what is expected of them throughout the module (Knowledge, basic level)
2) Name and point out local emergency procedures and facilities (Knowledge, basic level)
3) Discuss the relevant human factors and explain their implications (Knowledge, intermediate level)
ELEMENT 1.1 - SAFETY INSTRUCTIONS AND EMERGENCY PROCEDURES
Learning objective:
4) The participants can show interest or curiosity in the safety and emergency procedures at the training facility (ability, basic level)
The instructor shall:
Explain and ask open ended questions aiming at:
a. safety instructions according to internal procedures
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b. emergency procedures and emergency exits in the areas where the participants can be expected to be located during the course
The participants shall:
Engage in answering questions on local safety and emergency procedures
ELEMENT 1.2 - FACILITIES
Learning objective:
5) The participants can recognise the location of facilities at the training location (Knowledge, basic level)
The instructor shall:
Present a general description of the facilities at the training location (administration, dining area, restrooms, toilets, etc.)
Alternative activity: lead a tour and point out facilities
The participants shall:
Note relevant facilities and ask question when in doubt
ELEMENT 1.3 - INTRODUCTION
Learning objective:
6) The participants can show interest in fellow participants and the course content and design (Ability, basic level)
The instructor shall:
Explain and ask open ended questions on the Blade Repair Module training programme, including about breaks and mealtimes
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Give a short introduction to themselves including their backgrounds as instructors
Ask for participants’ expectations of the training, their learning and development
The participants shall:
Give a short introduction to themselves, including job function, expected primary geographic work location and share expectations on the training
ELEMENT 1.4 - SCOPE AND MAIN LEARNING OBJECTIVES
Learning objective:
7) The participants can recognise the scope and main objectives of the Blade Repair Module training (Knowledge, basic level)
The instructor shall:
Present the scope and main learning objectives of the Blade Repair Module training
Involve participants in questions on understanding and individual experiences on blade repair
The participants shall:
Engage in answering the above questions and share experiences of blade repair
ELEMENT 1.5 - ONGOING ASSESSMENTS (PARTICIPANT ASSESSMENT FORM)
Learning objective:
8) The participants can recognise the assessment procedure and the aim of the ongoing assessment (Knowledge, basic level)
The instructor shall:
Explain the reasons for the ongoing assessment
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Explain the layout of the GWO participant assessment form and how it will be used
The participants shall:
Engage themselves in discussions and ask questions when in doubt in relation to the assessment procedure
ELEMENT 1.6 - MOTIVATION
Learning objective:
9) The participants can show interest and willingness to engage in the learning activities (Ability, basic level)
The instructor shall:
Explain and lead discussion on:
a. the importance of personal involvement in the course
b. the definition of and the need for blade repair understandings and abilities
Positive motivation is the driving force for commitment. The instructor should make a focused effort to support growth of the necessary attitude and motivation in the participants
Note
The participants shall:
Engage themselves in discussion and share experiences on blade repair
When the participants succeed by trying out on their own, bringing their relevant experience into play and applying learning points from the instructor’s feedback, they develop a positive attitude and responsibility towards the subject and the performance in the work situation
Note
ELEMENT 1.7 - HUMAN FACTORS
The aim of the element is to draw the participant’s attention to how human behaviour and taking responsibility influences a safe work environment. The aim is additionally to prepare for a focus on human factors during practical training and exercises.
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