1 Table of contents 187

10032026 BladeRepair_V6

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 Target Group		10
5.2 Aims and Objectives		10
5.3 Validity Period		11
5.4 Course Codes		11
5.5 Participant Prerequisites for the Blade Repair Module		11
6. General Resources Required to Deliver Blade Repair Module		11
6.1 Instructors		11
6.2 Practical Training Facilities		12
6.3 Training Equipment		13
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 Aims and Objectives of the Blade Repair Module		17
9.2 Duration		18
9.3 Blade Repair Module Participant Ratio		18
9.4 Blade Repair Module Timetable		18
9.5 Detailed Description of the Blade Repair Module		24
Lesson 1 - Introduction to the training		24
ELEMENT 1.1 - Safety instructions and emergency procedures		24
ELEMENT 1.2 - Facilities		25
ELEMENT 1.3 - Introduction		25
ELEMENT 1.4 - Scope and main learning objectives		26
ELEMENT 1.5 - Ongoing assessments (participant assessment form)		26
ELEMENT 1.6 - Motivation		27
ELEMENT 1.7 - Human factors		27
Lesson 2 - Blade repair and legislative framework on chemical substances		29
ELEMENT 2.1 - legislative concepts		29
ELEMENT 2.2 - Downstream users		30
Lesson 3 - Safety data sheets		31
ELEMENT 3.1 - Safety Data Sheets		31
ELEMENT 3.2 - Safety data sheet location		32
ELEMENT 3.3 - Safety instructions		32
ELEMENT 3.4 - Hazard labels and symbols		33
Lesson 4 - Work instruction		34
ELEMENT 4.1 - Work instruction (WI)		34
ELEMENT 4.2 - Locate work instruction		35
Lesson 5 - Risk assessments		35
ELEMENT 5.1 - Risk assessments		36
Lesson 6 - Secure an area		37
ELEMENT 6.1 - Locate procedures		37
ELEMENT 6.2 - Securing the area		37
Lesson 7 - Contamination		38
ELEMENT 7.1 - Characteristics		38
ELEMENT 7.2 - Work instructions as mitigation		39
ELEMENT 7.3 - Avoiding contamination		39
Lesson 8 - Waste segregation		41
ELEMENT 8.1 - Correct waste segregation		41
ELEMENT 8.2 - Waste segregation information		42
Lesson 9 - Ergonomics		42
ELEMENT 9.1 - Classroom		43
ELEMENT 9.2 - Workshop		43
ELEMENT 9.3 - Bladework		43
Lesson 10 - Lock out tag out (LOTO)		44
ELEMENT 10.1 - Lock out tag out		44
Lesson 11 - Personal protective equipment		45
ELEMENT 11.1 - Types & Purpose		46
ELEMENT 11.2 - Application		46
ELEMENT 11.3 - Limitations		47
ELEMENT 11.4 - Task specific		47
ELEMENT 11.5 - Disposal		48
Lesson 12 - Masks and filters		49
ELEMENT 12.1 - Purpose		49
ELEMENT 12.2 - Filter categories		50
ELEMENT 12.3 - Categories and lifetime		50
ELEMENT 12.4 - Masks		51
ELEMENT 12.5 - Apply filters		52
Lesson 13 - Chemical safety		53
ELEMENT 13.1 - Purpose		53
ELEMENT 13.2 - Information about chemicals		54
ELEMENT 13.3 - Equipment check		54
ELEMENT 13.4 - Prevention and mitigation		55
ELEMENT 13.5 - Transfer procedures		56
Lesson 14 - Composites and blade construction		57
ELEMENT 14.1 - Aerodynamics		57
ELEMENT 14.2 - Blade construction		58
ELEMENT 14.3 - Sandwich panel		59
ELEMENT 14.4 - Blade enhancements		60
ELEMENT 14.5 - Faults, implications and mitigations		61
Lesson 15 - Materials		62
ELEMENT 15.1 - Reinforcement materials		62
ELEMENT 15.2 - Matrix materials		63
ELEMENT 15.3 - Adhesives		64
ELEMENT 15.4 - Surface coatings		65
ELEMENT 15.5 - Chemical handling and application		65
ELEMENT 15.6 - Curing		66
Lesson 16 - Tools and equipment		68
ELEMENT 16.1 - Mechanical, electrical and Pneumatic principles		68
ELEMENT 16.2 - Utilisation of tools and materials		69
ELEMENT 16.3 - Calibration		70
ELEMENT 16.4 - Lamination tools		71
ELEMENT 16.5 - Heating blankets		71
ELEMENT 16.6 - Checking electrical tools and equipment		72
ELEMENT 16.7 - Vibrating tools		73
ELEMENT 16.8 - Electrical safety devices		74
ELEMENT 16.9 - Documentation types		75
Lesson 17 - Phase test		76
ELEMENT 17.1 - Phase test		76
Lesson 18 - Lamination skills		76
ELEMENT 18.1 - Fibre orientation		77
ELEMENT 18.2 - Fibreglass mats		78
ELEMENT 18.3 - Kinked or bent fibres		78
ELEMENT 18.4 - Overlaps		79
ELEMENT 18.5 - Dry fibres and air voids		80
ELEMENT 18.6 - Mixing ratio		81
ELEMENT 18.7 - Calculation of matrix material		82
ELEMENT 18.8 - Curing at elevated temperatures		83
ELEMENT 18.9 - Ascertaining correct curing		84
ELEMENT 18.10 - Ambient temperature and humidity		85
ELEMENT 18.11 - Recording ambient temperature and humidity		86
Lesson 19 - Basic lamination		87
ELEMENT 19.1 - Minimise risks associated with Composite fibre work		87
ELEMENT 19.2 - Fibre orientation and moulding theory		88
Lesson 20 - Sandwich panel		90
ELEMENT 20.1 - Minimise risks associated with composite fibre work		91
ELEMENT 20.2 - Sandwich construction		91
ELEMENT 20.3 - Curing of fibre reinforced composite laminate		92
ELEMENT 20.4 - Producing a composite sandwich panel		95
ELEMENT 20.5 - Trailing edge section		97
Lesson 21 - Painting		98
ELEMENT 21.1 - Completion of blade		98
Lesson 22 - Blade inspection		100
ELEMENT 22.1 - Typical failures		100
ELEMENT 22.2 - Reactions to damage categories		101
ELEMENT 22.3 - Focused and scaled photographs		102
ELEMENT 22.4 - Tap test		103
ELEMENT 22.5 - Lighting		104
ELEMENT 22.6 - Inspection tools and methods		104
ELEMENT 22.7 - Types of damage		105
Lesson 23 - Inspection lightning protection system		106
ELEMENT 23.1 - Surface components		107
ELEMENT 23.2 - Visual and conductivity inspection		107
ELEMENT 23.3 - Measure resistance		108
Lesson 24 - Sanding skills		109
ELEMENT 24.1 - Sanding		110
Lesson 25 - Grinding skills		112
ELEMENT 25.1 - Grinding		112
Lesson 26 - Surface repairs		114
ELEMENT 26.1 - Minimise risks associated with composite fibre work		114
ELEMENT 26.2 - Filler adhesion		115
ELEMENT 26.3 - Reproduce surface profile		116
ELEMENT 26.4 - Paint adhesion		117
ELEMENT 26.5 - Layer thickness		117
ELEMENT 26.6 - Apply paint with a roller		118
ELEMENT 26.7 - Layer thickness with wet film		118
ELEMENT 26.8 - Record ambient temperature and humidity		119
ELEMENT 26.9 - Inspection and documentation		120
Lesson 27 - Laminate repairs		120
ELEMENT 27.1 - Minimise risks associated with composite fibre work		121
ELEMENT 27.2 - Safe removal of damaged material		121
ELEMENT 27.3 - Identifying fibre direction		122
ELEMENT 27.4 - Reinforcement overlaps and matrix adhesion		123
ELEMENT 27.5 - Mixing		124
ELEMENT 27.6 - Repair layers		125
ELEMENT 27.7 - Wetting out fibres using appropriate tools		126
ELEMENT 27.8 - Wetting out fibres with matrix material		126
ELEMENT 27.9 - Vacuum consolidation		127
ELEMENT 27.10 - Curing the repair using heating blankets		128
ELEMENT 27.11 - Verifying the curing		129
ELEMENT 27.12 - Recording the ambient temperature and humidity		130
Lesson 28 - Filling, shaping and finishing		131
ELEMENT 28.1 - Filler		131
Lesson 29 - Trailing edge repairs		132
ELEMENT 29.1 - Minimise risks associated with composite fibre work		133
ELEMENT 29.2 - Repair task		133
ELEMENT 29.3 - Crack repairs		134
ELEMENT 29.4 - Recreating blade profile		135
ELEMENT 29.5 - Record ambient temperature and humidity		136
Lesson 30 - Leading edge repairs		136
ELEMENT 30.1 - Minimise risks associated with composite fibre work		137
ELEMENT 30.2 - Repair task		137
ELEMENT 30.3 - Leading edge repair		138
ELEMENT 30.4 - Relocate leading edge		139
Lesson 31 - Sandwich panel repair		140
ELEMENT 31.1 - Minimise risks associated with composite fibre work		140
ELEMENT 31.2 - Repair task		141
ELEMENT 31.3 - Repair inner and outer laminate		141
ELEMENT 31.4 - Replacement core		143
ELEMENT 31.5 - Inspection and documentation		144
Lesson 32 - Bond line repairs		144
ELEMENT 32.1 - Debonding		145
ELEMENT 32.2 - Injection of adhesive		146
ELEMENT 32.3 - Injecting material in the trailing edge		147
Lesson 33 - Summary and final test		148
ELEMENT 33.2 - Summary		148
ELEMENT 33.3 - Final test		148
Lesson 34 - Training review		149
ELEMENT 34.1 - Training review		149
ELEMENT 34.2 - Feedback session		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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