GLOBAL WIND ORGANISATION STANDARD. Basic Maintenance Training (BMT) (Onshore/Offshore)

Transcription

1 GLOBAL WIND ORGANISATION STANDARD Basic Maintenance Training (BMT) (Onshore/Offshore) Version 0 21 March, 2016

2 Foreword The Global Wind Organisation (GWO) is an association of Wind Turbine owners and manufacturers with the aim of supporting an injury-free work environment in the wind industry. This Standard has been developed in response to the demand for recognisable Basic Maintenance Training in the industry. The development of this Standard has been prepared in co-operation between the members of GWO and has been based on work done by ATTP (Adapting a Transparent Training Programme for wind energy) in The objective of this Standard is to develop common industry training and Best Practice Standards for the basic technical and safety skills required for the service and maintenance of wind turbine generators across Europe and the globe. This Standard describes the requirements for Basic Maintenance Training in the wind industry that are recommended by GWO. Where national legislation sets higher requirements for the training, the Training Provider shall incorporate these requirements into the training programme. It is anticipated that additional Technical Training Programmes will be required due to company or country specific requirements. Page 2 / 111

3 EDITORIAL AND APPROVAL... 5 ACKNOWLEDGEMENT... 5 LIST OF ABBREVIATIONS... 5 INTRODUCTION... 6 TARGET GROUP... 6 OVERVIEW... 6 DURATION OF BMT MODULES... 6 LEGAL REQUIREMENTS... 7 VALIDITY PERIOD... 7 DELEGATE PREREQUISITES FOR THE BMT... 7 PHYSICAL DEMANDS... 7 AIMS AND OBJECTIVES... 8 RESOURCES FOR THE BMT MODULES... 8 ADMINISTRATION AND CERTIFICATION MODULE 1 - THE BMT HYDRAULICS MODULE Duration of the BMT Hydraulics Module Target Group Delegate prerequisites for the BMT Hydraulics Module Physical demands of the BMT Hydraulics Module Aims and objectives of the BMT Hydraulics Module Learning outcomes of the BMT Hydraulics Module Delegate Performance Assessment BMT Hydraulics Module Time Table Elements, BMT Hydraulics Module SECTION 2 - RESOURCES FOR BMT HYDRAULICS Instructors Instructor/Delegate Ratio Facilities Theoretical Training Facilities Practical Training Facilities Equipment SECTION 3 - ADMINISTRATION Delegate performance assessment Validity Measures Control Measures MODULE 2 THE BMT MECHANICAL MODULE Page 3 / 111

4 1.1 Duration of the BMT Mechanical Module Target Group Delegate prerequisites for the BMT Mechanical Module Physical demands of the BMT Mechanical Module Aims and objectives of the BMT Mechanical Module Learning outcomes of the BMT Mechanical Module Delegate Performance Assessment BMT Mechanical Module Time Table Elements, BMT Mechanical Module SECTION 2 RESOURCES FOR BMT MECHANICAL Instructors Instructor/Delegate Ratio Facilities Theory training facilities Practical training facilities Equipment SECTION 3 - ADMINISTRATION Delegate performance assessment Validity Measures Control Measures MODULE 3 - THE BMT ELECTRICAL MODULE Duration of the BMT Electrical Module Target Group Delegate prerequisites for the BMT Electrical Module Physical demands of the BMT Electrical Module Aims and objectives of the BMT Electrical Module Learning outcomes of the BMT Electrical Module Delegate Performance Assessment BMT Electric Module Time Table Elements, BMT Electric Module SECTION 2 RESOURCES FOR BMT ELECTRICAL Instructors Instructor/Delegate Ratio Facilities Theoretical training facilities Practical Training Facilities Equipment SECTION 3 ADMINISTRATION Delegate performance assessment Validity Measures Control Measures Page 4 / 111

5 Editorial and Approval The final editorial and approval of this standard has been conducted by the GWO Steering Committee. Acknowledgement The members of the Global Wind Organisation (GWO) recognise that training according to this Standard covers the requirements for Basic Maintenance Training for wind turbine technicians and personnel. GWO members agree that everyone working on one of their properties (Wind Turbine Generators, sub stations, etc.) shall complete Basic Maintenance Training courses relevant for their assignments. All work shall be done in teams of at a least 2 competent persons. Exemptions from the above can be made based on internal company rules. GWO Global Wind Organisation BMT Basic Maintenance Training WTG Wind Turbine Generator PPE Personal Protective Equipment LOTO Lock Out Tag Out List of Abbreviations Page 5 / 111

6 Introduction Upon completion of the Global Wind Organisation (GWO) Basic Maintenance Training (BMT) Delegates will possess an awareness of hydraulic, mechanical and electrical systems, preparing candidates for working both on and off shore in the wind power industry. Each of these training modules is not a stand-alone qualification but can be delivered independently of one another. Target Group The Basic Maintenance Training modules are targeted at candidates who have no previous experience of hydraulic, mechanical or electrical systems but may also be used to up skill candidates who have some knowledge of these areas in other spheres not specifically wind turbines. Overview The GWO Basic Maintenance Training is divided into the following three Modules: Hydraulics Mechanical Electrical Hydraulics Mechanical Electrical Duration of BMT Modules Modules Duration 16 hours 16 hours 20 hours Page 6 / 111

7 Legal Requirements The Training Provider shall identify whether national legislation sets other requirements for Basic Maintenance Training. If so, the Training Provider shall incorporate these identified requirements into the training. Validity Period The Basic Maintenance Modules are enduring qualifications and therefore a validity period does not apply to these modules. 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. Delegate Prerequisites for the BMT All personnel participating in Basic Maintenance Training shall be medically fit and capable of fully participating. Training providers shall have a procedure that requires Delegates to sign a statement (see Appendix 1A, Suggestion for Medical Statement from GWO) stating that they are medically fit to participate in the Maintenance Training and that they do not suffer from any medical illness or are under influence of any narcotic substance or alcohol. Delegates signatures shall be collected prior to the start of the training course. Physical Demands BMT 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. Page 7 / 111

8 Aims and Objectives This BMT Training shall enable Delegates to be able to perform basic hydraulics, mechanical and electrical tasks under the supervision of an experienced technician. Resources for the BMT Modules The Training Provider shall ensure that staff, facilities and equipment are in place to support the training of Delegates. Instructors Instructors shall possess the appropriate qualifications and experience to ensure that all training and supportive activities are carried out in accordance with current legislation. Instructors shall be: (1) Trained in instructional/lecture techniques and/or have documented/ instructional/ teaching experience. (2) Included in an on-going training programmes, which includes visits to onshore and/or offshore WTGs (tower, nacelle, hub) prior to instructing Basic Maintenance Training Modules, to enable them to maintain and update skills related to the modules they instruct. Instructors shall physically visit the tower, nacelle and hub of the WTGs. All instructors shall possess the appropriate competencies to conduct/assist the elements of training they have been assigned to. Facilities The full range of facilities shall be available during the training. The following facilities criteria shall be adhered to. Page 8 / 111

9 Theoretical Training Facilities The facilities shall be designed to enable each Delegate to see, hear and fully participate in the subject matter taught. Practical Training Facilities The facilities shall be designed to enable each Delegate to individually and/or as part of the team, see, hear and practice the subject matter taught. Note: All facilities shall be maintained and where appropriate, inspected and tested in accordance with current national legislation and manufacturers recommendation. Risk assessments shall be conducted and documented for all training facilities. The Training Provider shall hold the required permits to operate the facilities. Equipment The required equipment for training shall be available and fulfil national legal requirements. The equipment shall be maintained, inspected and tested in accordance with current national legislation and manufacturers recommendations. Risk assessments shall be conducted and documented for all training equipment. The Training Provider shall hold the required permits to operate relevant equipment. Page 9 / 111

10 Administration and Certification Administrative Arrangements Appropriate administrative arrangements for the enrolment and certification of Delegates and all aspects of the delivery of training shall be in accordance with this Standard. Delegate Performance Assessment Delegates shall be assessed according to the learning outcomes by means of direct observation and oral and/or written questions, where appropriate. Training Providers shall have a documented procedure in place for dealing with Delegates not meeting the stated learning outcomes. Certification Training Providers are responsible for issuing a certificate directly to the Delegate upon completion of the training programme and/or to the sponsoring company where required. Each certificate shall indicate that the Delegate has been assessed according to the learning outcomes and shall contain the following: (1) Training Provider s name (2) Full Basic Maintenance Training Module title stating the training module is GWO approved (3) Delegate s name (4) Course dates (5) Training Provider s signature Records The Training Provider shall keep a record of Delegates that have completed the GWO BMT for a minimum period of 5 years. Upon request from GWO or any of the members of GWO, the Training Provider shall be able to verify the training and competence records of any specific personnel by name. BMT Modules The requirements for each of the Basic Maintenance Training Modules are outlined in the following sections. Page 10 / 111

11 GLOBAL WIND ORGANISATION STANDARD Basic Maintenance Training (BMT) (Onshore/Offshore) HYDRAULICS MODULE Version 0 21 March, 2016 Page 11 / 111

12 Module 1 - The BMT Hydraulics Module 1.1 Duration of the BMT Hydraulics Module The optimal total time for completing this BMT Hydraulics Module is minimum 16 hours, including meals and breaks. The practical skills shall be trained and demonstrated, and all elements of the course shall be covered by demonstration where possible. If this training is part of a programme of longer duration, the total contact time per day shall not exceed 8 hours and the total training day shall not exceed 10 hours. The total training day includes contact time, refreshment and meal breaks and travel between training sites where applicable. 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 BMT training course will still be taught as per the lesson plan whether the Delegate has prior experience or not. 1.2 Target Group The Basic Maintenance Training (BMT) is designed to provide Delegates with the basic maintenance skills that together with the needed safety courses - will enable the Delegates to work onsite, supervised by an experienced technician. The Hydraulics Training module is targeted at personnel with little or no previous experience of hydraulic systems. It will give them the basic skills and knowledge to carry out basic maintenance tasks using safe working procedures and the correct PPE. Page 12 / 111

13 1.3 Delegate prerequisites for the BMT Hydraulics Module There are no prerequisites for this module 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. 1.4 Physical demands of the BMT Hydraulics Module BMT 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. Page 13 / 111

14 1.5 Aims and objectives of the BMT Hydraulics Module The aim of the BMT Hydraulics Module is to give the Delegates the knowledge and skills to carry out basic hydraulics maintenance tasks (supervised by an experienced technician), using safe working procedures and the correct PPE. The BMT Hydraulic Module shall ensure that: (1) The Delegates are able to explain the basics of Pascal s Law (2) The Delegates are able to explain risks and hazards associated with hydraulic work (3) The Delegates are able to demonstrate the use of PPE when operating hydraulic systems (4) The Delegates are able to explain the importance of Lock Out Tag Out and demonstrate the principles involved (5) The Delegates are able to explain the basics of hydraulic systems including their components and symbols (6) The Delegates are able to explain the different types and the function of pumps in the hydraulic system and demonstrate how to check start/stop pressure of a pump (7) The Delegates are able to explain the different types and the function of actuators in the hydraulic system (8) The Delegates are able to explain the different types and the function of valves in the hydraulic system (9) The Delegates are able to demonstrate how to relieve pressure within a system (10) The Delegates are able to explain the different types and the function of accumulators in the hydraulic system, including demonstration of safe working procedures for checking and recharging of accumulators (11) The Delegates are able to explain the different types of sensors in the hydraulic system, their location and function. (12) The Delegates are able to identify pipes, hoses and connections in the hydraulic system Page 14 / 111

15 (13) The Delegates are able to describe the different types of oils and filters, including the handling procedures, functions and maintenance and demonstrate how to check oil level (14) The Delegates are able to demonstrate how to use pressure gauges/manometers (15) The Delegates are able to identify several hydraulic components within a diagram Page 15 / 111

16 1.6 Learning outcomes of the BMT Hydraulics Module The learning outcomes specified for the Hydraulics Module are: Lesson 1 30 min. Introduction The aim of this lesson is to give the Delegates the needed awareness of the course content and the facilities involved in order to ensure that all Delegates are aware of what to expect and what is expected of them during the course. To successfully complete this BMT Module, Delegates shall be aware of: (1) Safety instructions and emergency procedures (2) Facilities (3) Who the instructor and other Delegates are (4) The aims and main learning objectives (5) On-going assessment according to GWO Control Measures (6) Motivation on the course Note: The administrative part of the registration should be carried out before the course commences. Lesson 2 30 min. Hydraulics Introduction The aim of this lesson is to give the candidates sufficient knowledge about the hydraulic systems. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the function and principles of a basic hydraulic system (2) Explain hydraulic power transmission/pascal s Law (3) Give examples of transmission ratio Page 16 / 111

17 Lesson 3 45 min. Risks and hazards The aim of this lesson is to give the Delegates the needed knowledge and understanding of possible hydraulic hazards in a wind turbine. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the risks and hazards of high pressure in hydraulic systems (2) Explain the risks and hazards of oil in hydraulic systems (3) Explain the safety conditions required to work with the accumulator (4) Explain the need of MSDS sheets Lesson 4 Hydraulic PPE 30 min. The aim of this lesson is to train the Delegates to be able to choose the right PPE for working with hydraulics and to test it before use. To successfully complete this BMT Module, Delegates shall be able to: (1) Demonstrate which PPE can be used for hydraulic work (2) Demonstrate how to test that the PPE is fit for use (3) Demonstrate the correct use of PPE Lesson 5 60 min. Prevention of un-expected start up The aim of this lesson is to make the Delegates aware of the importance of Lock Out Tag Out procedures and demonstrate the principals involved. To successfully complete this Module, Delegates shall be able to: (1) Explain the importance of Lock Out Tag Out (2) Demonstrate an example of Lock Out Tag Out Page 17 / 111

18 Lesson 6 Pumps 60 min. The aim of this lesson is to train the Delegates to be able to explain the main type of pumps of hydraulic circuits and demonstrate how to check the start and stop pressure on pumps. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the principle of the working of piston pumps (2) Explain the principle of the working of gear pumps (3) Demonstrate how to check the start and stop pressure of a pump following the instructions Lesson 7 30 min. Actuator The aim of this lesson is to train the Delegates to be able explain the main type of actuators (e.g. cylinders) in a hydraulic circuit. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the different types of actuators, and their use Lesson 8 Directional control valves 45 min. The aim of this lesson is to train the Delegates to be able to explain the function and operation of the directional control valves in a hydraulic circuit. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the different types of directional valves, and describe the principle of operation of the different directional valves (2) Explain the operation of the directional valves Page 18 / 111

19 Lesson 9 30 min. Proportional valves The aim of this lesson is to enable the Delegates to explain the function of proportional valves in a hydraulic circuit. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the function of a proportional valve in a circuit and how it works Lesson 10 Pressure and flow valves 90 min. The aim of this lesson is to enable the Delegates to explain the function and operation of the different valves in a circuit and demonstrate how to operate a needle valve and adjust a pressure relief valve To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the different pressure and flow valves in a circuit (2) Demonstrate how to check and adjust the pressure relief valve (3) Explain the principle of the operation of a pressure reduction valve (4) Demonstrate how to operate a needle valve (5) Explain the principle of the operation of a non-return valve (6) Explain the principle of the operation of a Throttle valve (7) Explain the principle of the operation of an orifice/restrictor valve Lesson min. Accumulators The aim of this lesson is to train the Delegates to be able to explain about the different types and the function of accumulators and demonstrate how to check accumulators under safe conditions. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the function of the accumulators in the circuit (2) Explain the different types of accumulator and their different parts (3) Explain the handling and storage of the nitrogen bottles (4) Demonstrate how to check the pre-charge pressure and refill the accumulator Page 19 / 111

20 Lesson min. Sensors The aim of this lesson is to enable the Delegates to be able to explain the different sensors and their function in a hydraulic circuit. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the function of the pressure transducer and pressure switch (2) Explain the function of a temperature sensor (3) Explain the function of a flow sensor Lesson min. Pipes, hoses and connections The aim of this lesson is to enable the Delegates to be able to identify the pipes system and its elements. To successfully complete this BMT Module, Delegates shall be able to: (1) Identify the transfer fluid network and its risks (2) Describe the pipes, hoses and hydraulic connections Lesson min. Oil and filters The aim of this lesson is to train the Delegates to be able to describe the different type of oil and filters, including the handling procedures, functions and maintenance. Demonstrate how to check oil level. To successfully complete this BMT Module, Delegates shall be able to: (1) Describe different types of oils (2) Describe the handling of oil procedures and cleanliness (3) Describe the importance of an oil sample (4) Demonstrate how to check oil level (5) Describe different types of filters and their function (6) Describe the filter conditions and their maintenance Page 20 / 111

21 Lesson min. Pressure gauges/manometers The aim of this lesson is to train the Delegates to be able to demonstrate how to measure the hydraulic pressure accurately. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the characteristic and symbol of pressure gauges/manometers (2) Demonstrate how to check calibration (3) Demonstrate the measurement of hydraulic pressure Lesson 16 Symbols and diagrams 60 min. The aim of this lesson is to train the Delegates to be able to identify and find the different elements of a hydraulic installation. To successfully complete this BMT Module, Delegates shall be able to: (1) Identify the main symbols and components in a diagram of a hydraulic system (e.g. pump, tank, hoses, valves) (2) Identify the measuring points in a diagram of a hydraulic system Lesson min. Hydraulic Theory Test The aim of this lesson is to test the Delegates theoretical knowledge of hydraulic systems, and to discuss the result of the test with the Delegates. Page 21 / 111

22 Lesson 18 Evaluation 30 min. The aim of this lesson is to summarize the BMT Module and to give the Delegates the opportunity to conduct an open-minded review of the training and the instructor. To successfully complete this BMT Module, Delegates shall be able to demonstrate: 1) Active participation in the evaluation Page 22 / 111

23 1.7 Delegate Performance Assessment Assessment of learning outcomes: Delegates will be assessed according to the learning outcomes stated in section 1.6 by means of direct observation, supplementary oral questions when appropriate and a written test to cover the mechanical theory. The direct observation is to be conducted by practical scenarios on a WTG environment. Each Delegate shall demonstrate: (1) Safe working procedures for hydraulic work (2) Correct and proper methods of working with hydraulic systems The formal evaluation of knowledge of above scenarios shall be in accordance with the Control Measures in Section 3 (Measures). The Training Provider shall have a documented procedure in place for dealing with persons not meeting the stated learning outcomes. At least 70% of the questions in the written test must be answered correctly in order to pass the test. Page 23 / 111

24 1.8 BMT Hydraulics Module Time Table The order in which the elements of the Training Module are delivered may vary. Lesson 1 Introduction Hydraulics introduction Risks and hazards Hydraulic PPE Prevention of unexpected start-up Element Safety instructions and emergency procedures Facilities Introduction Scope and main objectives On-going assessments Motivation TOTAL The hydraulic system Pascal s law Transmission ratio TOTAL High pressure systems Oil TOTAL Types of PPE Proper inspections Correct uses TOTAL 5.1 Importance of Lock Out Tag Out TOTAL 6 Pumps 6.1 Gear pumps 6.2 Piston pumps 6.3 Pumps exercise TOTAL 7 Actuator 7.1 Types 7.2 Hydraulic cylinders TOTAL 8 Directional control valves 8.1 Types Approximate Duration 30 min. 30 min. 45 min. 30 min. 60 min. 60 min. 30 min. TOTAL 9 Proportional valves 9.1 Principle of operation TOTAL 45 min. 30 min. Page 24 / 111

25 10 Pressure and flow valves Accumulators Sensors Pressure relief valves Pressure reduction valves Needle valves Non return valves Throttle valves Orifice/restrictor valves TOTAL Use and types Safety Pre-charge pressure TOTAL Pressure sensors Temperature sensors Flow sensors 90 min. 90 min. 13 Pipes, hoses and connections TOTAL Oil Transfer Hydraulic connections 30 min. 14 Oil and filters TOTAL Oil Handling oil procedures/cleanliness Collecting an oil sample Check oil level Filters 30 min. 15 Pressure gauges/manometers Symbols and Diagrams TOTAL Pressure gauge/manometer characteristics Check calibration Pressure measuring TOTAL Main symbols and components Identifying measuring points 60 min. 30 min. 17 Hydraulic Theory Test 17.1 Test 18 Evaluation GRAND TOTAL Summary Evaluation Certificates TOTAL TOTAL 60 min. 60 min. 30 min. 840 min. Page 25 / 111

26 1.9 Elements, BMT Hydraulics Module Lesson 1 Introduction ELEMENT 1.1 Safety instructions and emergency procedures Safety instructions according to internal procedures Emergency procedures and emergency exits in the localities the Delegates can be expected to be located during the course ELEMENT 1.2 Facilities General description of the facilities on the location (Administration, dining area, restrooms and toilets, etc.) ELEMENT 1.3 Instructors shall give: Introduction A short presentation of himself including his background as an instructor Delegates shall give: A short introduction, including job function expectation for the course The programme of the BMT Module, including breaks and meal times Page 26 / 111

27 ELEMENT 1.4 Scope and main objectives Scope and main objectives of this BMT Module ELEMENT 1.5 On-going assessments The reasons for the on-going assessment GWO Control Measures and their use ELEMENT 1.6 Motivation The importance of personal involvement in the course Lesson 2 Hydraulics introduction ELEMENT 2.1 The hydraulic system Introduction to pressure The typical components in a hydraulic system (e.g. pump, tank, hoses, valves) ELEMENT 2.2 Pascal s law The basic concept regarding the incompressibility of fluid and how force can be transferred from one cylinder to another Practical examples of Pascal s law Page 27 / 111

28 ELEMENT 2.3 Instructors shall lead discussion of: Transmission ratio How it is possible to increase and decrease the force by using the same pressure Lesson 3 Risks and hazards ELEMENT 3.1 High pressure systems Instructors shall explain and lead discussion of: The hazards caused by exposure to high pressure oil (e.g. cuts, oil injections) and nitrogen (e.g. nitrogen in the lungs, high pressure, stored energy, cold burns, squeeze and punch) The importance of checking and relieving system pressure including accumulators (e.g. test points, manometers and needle valves) ELEMENT 3.2 Oil Instructors shall explain and lead discussion of: The hazards caused by being exposed to hydraulic oil The need of Material Safety Data Sheets (MSDS) Lesson 4 Hydraulic PPE ELEMENT 4.1 Types of PPE Instructors shall explain and demonstrate: A glove suitable for hydraulic work That not all gloves are suitable for hydraulic work The consequence of not wearing the right PPE Which goggles can be used for hydraulic work The importance of wearing goggles when working with hydraulic systems Page 28 / 111

29 ELEMENT 4.2 proper inspections Instructors shall explain and demonstrate: How to test if the glove is fit for use (1) Check the glove for holes (2) Check that the glove is suitable for hydraulic oil ELEMENT 4.3 Correct use Instructors shall practice and demonstrate: How to choose the right PPE to wear for hydraulic work How to inspect and use hydraulic PPE Lesson 5 Prevention of un-expected start-up ELEMENT 5.1 Instructors shall explain and demonstrate: Importance of Lock Out Tag Out The importance of Lock Out Tag Out An example of the procedure for Lock Out Tag Out Delegates shall engage in discussions of: Why it is important to prevent unexpected start-up Delegates shall practice and demonstrate: An example of the procedure for Lock Out Tag Out Page 29 / 111

30 Lesson 6 Pumps ELEMENT 6.1 Gear pumps Instructors shall explain and demonstrate: The parts of a gear pump How a gear pump works The symbol used in the diagram ELEMENT 6.2 Piston pumps Instructors shall explain and demonstrate: The parts of a piston pump How a piston pump works The symbol used in the diagram ELEMENT 6.3 Pumps exercise Instructors shall explain and demonstrate: The process to check the start and stop pressure on a pump Delegates are to practice and demonstrate: How to check the start and stop pressure on a pump following the instructions from the trainer Lesson 7 Actuators ELEMENT 7.1 Types The different types of actuators (e.g. cylinders and callipers) The use of each type of actuator The symbol for an actuator Page 30 / 111

31 ELEMENT 7.2 Hydraulic cylinders Examples of faulty cylinders (e.g. pistons) The hazards which may occur (e.g. causes of leaks and pressure drop) Lesson 8 Directional control valves ELEMENT 8.1 Types The different types of directional valves (e.g. 2/3, 3/4) The principle of operation of directional valves That the directional control valve has been named based on how many ports and positions it has That valves are shown de-energised in the diagram The difference between an electrical operated valve and a pilot operated valve The symbol for an electrical operated valve and pilot operated valve Delegates are to engage in discussions of: The operation of directional valves Lesson 9 Proportional valves ELEMENT 9.1 Principle of operation The use of proportional valves in a hydraulic circuit The principle of operation of the proportional valves The symbol for a proportional valve Delegates are to engage in discussions of: The operation of a proportional valve in a circuit Page 31 / 111

32 Lesson 10 Pressure and flow valves ELEMENT 10.1 Pressure relief valves Instructors shall explain and demonstrate: The function of the pressure relief valve and how it works The position of a pressure relief valve in a circuit How to check and adjust the pressure relief valve The symbol for a pressure relief valve Delegates are to practice and demonstrate: Checking and adjusting the pressure relief valve in a circuit ELEMENT 10.2 Pressure reduction valves Instructors shall explain and demonstrate: The function of the pressure reduction valve and how it works The position of a pressure reduction valve in a circuit The symbol for a pressure reduction valve ELEMENT 10.3 Needle valves Instructors shall explain and demonstrate: The function of the needle valve in a circuit The position of a needle valve in a circuit The symbol for a needle valve Delegates are to practice and demonstrate: The operation of the needle valve in a circuit The use of a needle valve to depressurize the hydraulic system Page 32 / 111

33 ELEMENT 10.4 Non return valves The function of a non-return valve The function of a pilot operated non-return valve The position of a non-return valve in a circuit The symbol for a non-return valve The symbol for a pilot operated non-return valve ELEMENT 10.5 Throttle valves The function of a throttle valve The position of a throttle valve in a circuit The symbol for a throttle valve ELEMENT 10.6 Orifice/restrictor valves The function of an orifice/restrictor valve The position of an orifice/restrictor valve in a circuit The symbol for an orifice/restrictor valve Lesson 11 Accumulator ELEMENT 11.1 Use and types Instructors shall explain and demonstrate: The different types of accumulators (bladder, piston and diaphragm) The function of the accumulators in a circuit The symbol for an accumulator Page 33 / 111

34 ELEMENT 11.2 Safety Instructors shall explain and demonstrate: Principal characteristics of Nitrogen Nitrogen bottles storage and handling requirements The importance of discharging the accumulators prior to working on the system The risks associated with a charged accumulator ELEMENT 11.3 Pre-charge pressure Instructors shall explain and demonstrate: How to check the pre-charge pressure of an accumulator The temperature correction chart Delegates shall practice and demonstrate: How to check the pre-charge pressure of an accumulator How to refill the accumulator Lesson 12 Sensors ELEMENT 12.1 Pressure sensors The function of the pressure transducer and pressure switch The position of the pressure transducer and pressure switch in a circuit The symbol for a pressure transducer and pressure switch ELEMENT 12.2 Temperature sensors The function of the temperature sensor The position of the temperature sensor in a circuit The symbol for a temperature sensor Page 34 / 111

35 ELEMENT 12.3 Flow sensors The function of the flow sensor The position of the flow sensor in a circuit The symbol for a flow sensor Delegates shall engage in discussions of: Different types, location and functions of sensors Lesson 13 Pipes, hoses and connections ELEMENT 13.1 Oil Transfer Instructors shall describe: The function of hydraulic pipes and hoses The position of the pipes and hoses in a circuit The different types of pipes, hoses and fittings used in hydraulic systems The symbol for a hose The risks and hazards associated with pipes and hoses ELEMENT 13.2 Hydraulic connections Instructors shall describe: How to make a connection with different fittings The function of quick release couplings The symbol for a quick release coupling Lesson 14 Oil and filters ELEMENT 14.1 Oil Instructors shall describe: The characteristics of different types of oil Page 35 / 111

36 ELEMENT 14.2 Handling oil procedures/cleanliness Instructors shall describe: The personal safety involved when handling oil The environmental safety involved when handling oil The importance of cleanliness ELEMENT 14.3 Collecting an oil sample Instructors shall describe: The importance of collecting an oil sample ELEMENT 14.4 Checking oil level Instructors shall explain and demonstrate: The function of the tank Oil level checking with a dip stick Oil level checking with a sight glass Oil level checking with a filling hole Delegates shall practice and demonstrate: The procedures for checking oil level with a dip stick, sight glass and filling hole ELEMENT 14.5 Filters Instructors shall describe: The function of the filters The different types of filters The particle sizes The importance of replacing filters The symbol for filters The position of filters in a circuit Page 36 / 111

37 Lesson 15 Pressure gauges/manometers ELEMENT 15.1 Pressure gauge/manometer characteristics Instructors shall explain and demonstrate: The characteristic of pressure gauges/manometers The symbol for a pressure gauge/manometer Delegates shall engage in discussions of: How to use a pressure gauge/manometer ELEMENT 15.2 Checking calibration Instructors shall demonstrate: How to check that a pressure gauge is calibrated Delegates are to practice and demonstrate: Checking the calibration of pressure gauges ELEMENT 15.3 Pressure measuring Instructors shall demonstrate: How to take an accurate pressure measurement Delegates are to practice and demonstrate: How to measure the hydraulic pressure accurately Page 37 / 111

38 Lesson 16 Symbols and diagrams ELEMENT 16.1 Main symbols and components Instructors shall summarise: The symbols that represent each components of a hydraulic circuit The symbols of the main elements in a diagram ELEMENT 16.2 Identifying measuring points The accurate measuring points in a circuit The symbol of measuring points Delegates shall engage in discussions of: Hydraulic systems and the symbols used in hydraulic circuit diagrams Identifying accurate measuring points using a diagram Lesson 17 Hydraulic theory test ELEMENT 17.1 Test Instructors shall: Conduct the test with the delegates Delegates shall: Conduct the test within 30 minutes Instructors shall: Check the test results and give feedback to the Delegates about the test result Page 38 / 111

39 Lesson 18 Evaluation ELEMENT 18.1 Summary Instructors shall: Summarise the BMT Module and give the Delegates final feedback ELEMENT 18.2 Evaluation Delegates shall: Conduct a written evaluation Instructors shall: Give necessary feedback on the written evaluations ELEMENT 18.3 Certificates Instructors shall: Hand out certificates and ensure that all Delegates are registered with the correct personal information on the certificate Notes: The course is summarised and ended. At the end of the course the Delegates are asked to share their new knowledge and to spread the GWO-maintenance-spirit to their colleagues. Another purpose is to allow Delegates to both orally and in written form evaluate their instructors and the content of the course. Finally, the certificates are handed out. Page 39 / 111

40 Section 2 - Resources for BMT Hydraulics The Training Provider shall ensure that instructors, facilities and equipment are in place to support the training of the Delegates. 2.1 Instructors Instructors shall possess appropriate qualifications and experience to ensure that all training and supportive activities are carried out in accordance with current legislation. Instructors shall be: (1) Trained in instructional/lecture techniques and/or have documented instructional/teaching experience (2) Included in an on-going training programme, which includes visits to onshore and/or offshore WTGs (tower, nacelle, hub) prior to instructing BMT Modules, to enable them to maintain and update skills related to the BMT Modules they instruct All staff shall possess the appropriate competencies to conduct/assist the elements of training they have been assigned to. 2.2 Instructor/Delegate Ratio (1) The ratio shown for the theory session indicate the maximum number of Delegates attending the course. (2) Other ratios indicate the maximum number of Delegates to be supervised by an instructor during each activity. Module Session Instructor Delegate Ratio Theory 1:12 BMT Hydraulics Module Practical 1:6 Page 40 / 111

41 2.3 Facilities The full range of facilities shall be available during the training. The following facility criteria shall be adhered to. 2.4 Theoretical Training Facilities Facilities shall be designed to enable each Delegate to see, hear and fully participate in the taught subject matter. A room is required that has projection facilities, a white board and desks for the Delegates to write on. 2.5 Practical Training Facilities Shall be designed to enable each Delegate to individually and/or as part of a team, see, hear and practice the taught material. A practical workshop is required that has enough space to accommodate 6 candidates, with a respective work area each of approximately 3 square meters. Note: All facilities shall be maintained and where appropriate, inspected and tested in accordance with current national legislation and manufacturers recommendations. Risk assessments shall be conducted and documented for all training facilities. The Training Provider shall hold the required permits to operate facilities. Page 41 / 111

42 2.6 Equipment The following equipment is required during the entire duration of this BMT Hydraulics Training to meet the need of the BMT Hydraulics Module: There will need to be basic tool kits for the candidates that contain spanners, torque wrenches, and any other equipment associated with hydraulics. All necessary PPE must be provided (goggles, specific gloves, overalls and boots). There must be hydraulic rigs where components can be assembled to produce simple hydraulic circuits. There must be a rig with pre-built electrical control of a hydraulic circuit that contains the following components: (1) PPE suitable for hydraulic work (2) LOTO equipment (3) Tank (4) Pump with electrical motor (5) Directional valve (6) Needle valve (7) Pressure relief valve (8) Non-return valve (9) Pressure switch (10) Actuator (11) Accumulator (12) Test points (13) Oil (14) Filters (15) Pressure gauge/manometer (16) Filling kit for nitrogen (17) Nitrogen In order to comply with national legislation and standards, the equipment supplied and used by staff and Delegates shall follow the appropriate guidelines, e.g.: Europe EN USA ANSI Australia and New Zealand AS/NZS UK BS Canada CSA Asia ANSI / EN Note: All equipment shall be maintained and where appropriate, inspected and tested in accordance with current national Standards/legislation and manufacturers recommendations. Page 42 / 111

43 Section 3 - Administration 3.1 Delegate performance assessment Delegates shall be assessed according to the learning outcomes by means of direct observation and oral and/or written questions, where appropriate. Training Providers shall have a documented procedure in place for dealing with Delegates not meeting the stated learning outcomes. 3.2 Validity A maximum interval between successful completions of the BMT Hydraulics Module does 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. 3.3 Measures The Instructor keeps the Control Measures Forms until the completion / evaluation of the BMT Module. If a Delegate fails to meet the demands, they shall attend a new BMT Hydraulics Module. 3.4 Control Measures Please find the Control Measures Form on next page. Page 43 / 111

44 Name: Course: BMT Hydraulics Module Date: Training Provider: Scenario Organisation Aware of personal and group safety at all times Violation of Assessment Measures 0-2 Passed/ 3 Failed Instructor Remarks Organises and utilises correct equipment for given scenario Scenario Management Establishes and maintains control of the exercise scenario at all times Fully participates in the exercise scenario Follows directions when required Demonstrates correct and safe manual handling in exercise scenario Knowledge and Understanding Applies subject knowledge correctly in given scenario Page 44 / 111

45 Demonstrates understanding of subject Total Marks 0 9 Pass Fail Instructor: PASS FAIL The practical Assessment Measures Form 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 can 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 when a Delegate fails the Module. Page 45 / 111

46 GLOBAL WIND ORGANISATION STANDARD Basic Maintenance Training (BMT) (Onshore/Offshore) MECHANICAL MODULE Version 0 21 March, 2016 Page 46 / 111

47 Module 2 The BMT Mechanical Module 1.1 Duration of the BMT Mechanical Module The optimal total time for completing this BMT Mechanical Module is minimum 16 hours, including meals and breaks. The practical skills shall be trained and demonstrated, and all elements of the course shall be covered by demonstration where possible. If this training is part of a programme of longer duration, the total contact time per day shall not exceed 8 hours and the total training day shall not exceed 10 hours. The total training day includes contact time, refreshment and meal breaks and travel between training sites where applicable. 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 BMT training course will still be taught as per lesson plan whether the Delegate has prior experience or not. 1.2 Target Group The Basic Maintenance Training (BMT) is designed to provide Delegates with the basic maintenance skills that together with the needed safety courses - will enable the Delegates to work onsite, supervised by an experienced technician. The Mechanical Training module is targeted at personnel with little or no previous experience of mechanical systems. It will give them the basic skills and knowledge to carry out basic maintenance tasks using safe working procedures and the correct PPE. Page 47 / 111

48 1.3 Delegate prerequisites for the BMT Mechanical Module There are no prerequisites for this module 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. 1.4 Physical demands of the BMT Mechanical Module BMT 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. Page 48 / 111

49 1.5 Aims and objectives of the BMT Mechanical Module The aim of this BMT Mechanical Module is to give the Delegates the knowledge and skills to carry out basic mechanical maintenance tasks (supervised by an experienced technician) using safe working procedures and the correct PPE. The BMT Basic Mechanical Module shall ensure that: (1) The Delegates are able to understand safety precautions, the necessary PPE and the appropriate tools required (2) The Delegates are able to understand the main components; foundation, tower, nacelle, rotor and blades, platforms, ladders and lift (3) The Delegates are able to understand the main mechanical systems and their components; pitch system, yaw system, drive train, gearbox, coupling, and generator (4) The Delegates are able to understand the lubrication systems, the types of oil and grease used and their disposal to environmental standards. They will understand Oil Cleanliness rating and its impact on component performance. (5) The Delegates are able to understand the principles of threads and threaded components; and the maintenance of bolted connections (6) The Delegates are able to understand force, torque, energy, wind speed and wind direction (7) The Delegates are able to demonstrate how to use spanners, torque wrenches, screwdrivers, feeler gauges, callipers and dial gauges to carry out prescribed checks (8) The Delegates are able to explain the basic function of a laser alignment tool (9) The Delegates are able to explain how to inspect various components for wear, leaks, damage, corrosion, cracks and malfunction and demonstrate how to inspect a cooling system/or lubrication system. Page 49 / 111

50 1.6 Learning outcomes of the BMT Mechanical Module The learning outcomes specified for the Basic Mechanical Module are: Lesson 1 Introduction 15 min. The aim of this lesson is to give the Delegates the needed awareness of the course content and the facilities involved in order to ensure that all Delegates are aware of what to expect and what is expected of them during the course. To successfully complete this BMT Module, Delegates shall be aware of: (1) Safety instructions and emergency procedures (2) Facilities (3) Who the instructor and other Delegates are (4) The aims and main learning objectives (5) On-going assessment according to GWO Control Measures (6) Motivation on the course Note: The administrative part of the registration should be carried out before the course commences. Lesson 2 90 min. Mechanical Introduction The aim of this lesson is to give the Delegates sufficient basic understanding of mechanical systems in a WTG. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the main components in a wind turbine (2) Explain the main mechanical systems in a wind turbine (3) Explain how a wind turbine works, including the physics which influence the output of wind turbines. Including energy, wind speed and wind direction (4) Explain the risks and hazards on mechanical systems Page 50 / 111