GLOBAL WIND ORGANISATION STANDARD Basic Maintenance Training (BMT) (Onshore/Offshore) Version 0 21 March, 2016
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 2014. 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
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... 10 MODULE 1 - THE BMT HYDRAULICS MODULE... 12 1.1 Duration of the BMT Hydraulics Module... 12 1.2 Target Group... 12 1.3 Delegate prerequisites for the BMT Hydraulics Module... 13 1.4 Physical demands of the BMT Hydraulics Module... 13 1.5 Aims and objectives of the BMT Hydraulics Module... 14 1.6 Learning outcomes of the BMT Hydraulics Module... 16 1.7 Delegate Performance Assessment... 23 1.8 BMT Hydraulics Module Time Table... 24 1.9 Elements, BMT Hydraulics Module... 26 SECTION 2 - RESOURCES FOR BMT HYDRAULICS... 40 2.1 Instructors... 40 2.2 Instructor/Delegate Ratio... 40 2.3 Facilities... 41 2.4 Theoretical Training Facilities... 41 2.5 Practical Training Facilities... 41 2.6 Equipment... 42 SECTION 3 - ADMINISTRATION... 43 3.1 Delegate performance assessment... 43 3.2 Validity... 43 3.3 Measures... 43 3.4 Control Measures... 43 MODULE 2 THE BMT MECHANICAL MODULE... 47 Page 3 / 111
1.1 Duration of the BMT Mechanical Module... 47 1.2 Target Group... 47 1.3 Delegate prerequisites for the BMT Mechanical Module... 48 1.4 Physical demands of the BMT Mechanical Module... 48 1.5 Aims and objectives of the BMT Mechanical Module... 49 1.6 Learning outcomes of the BMT Mechanical Module... 50 1.7 Delegate Performance Assessment... 54 1.8 BMT Mechanical Module Time Table... 56 1.9 Elements, BMT Mechanical Module... 58 SECTION 2 RESOURCES FOR BMT MECHANICAL... 72 2.1 Instructors... 72 2.2 Instructor/Delegate Ratio... 72 2.3 Facilities... 73 2.4 Theory training facilities... 73 2.5 Practical training facilities... 73 2.6 Equipment... 73 SECTION 3 - ADMINISTRATION... 75 3.1 Delegate performance assessment... 75 3.2 Validity... 75 3.3 Measures... 75 3.4 Control Measures... 75 MODULE 3 - THE BMT ELECTRICAL MODULE... 79 1.1 Duration of the BMT Electrical Module... 79 1.2 Target Group... 80 1.3 Delegate prerequisites for the BMT Electrical Module... 80 1.4 Physical demands of the BMT Electrical Module... 80 1.5 Aims and objectives of the BMT Electrical Module... 81 1.6 Learning outcomes of the BMT Electrical Module... 82 1.7 Delegate Performance Assessment... 88 1.8 BMT Electric Module Time Table... 89 1.9 Elements, BMT Electric Module... 91 SECTION 2 RESOURCES FOR BMT ELECTRICAL... 106 2.1 Instructors... 106 2.2 Instructor/Delegate Ratio... 106 2.3 Facilities... 106 2.4 Theoretical training facilities... 107 2.5 Practical Training Facilities... 107 2.6 Equipment... 108 SECTION 3 ADMINISTRATION... 109 3.1 Delegate performance assessment... 109 3.2 Validity... 109 3.3 Measures... 109 3.4 Control Measures... 109 Page 4 / 111
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
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
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
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
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
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
GLOBAL WIND ORGANISATION STANDARD Basic Maintenance Training (BMT) (Onshore/Offshore) HYDRAULICS MODULE Version 0 21 March, 2016 Page 11 / 111
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
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
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
(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
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
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
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
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 11 90 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
Lesson 12 30 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 13 30 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 14 60 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
Lesson 15 30 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 17 60 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
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
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
1.8 BMT Hydraulics Module Time Table The order in which the elements of the Training Module are delivered may vary. Lesson 1 Introduction 1.1 1.2 1.3 1.4 1.5 1.6 2 Hydraulics introduction 2.1 2.2 2.3 3 Risks and hazards 3.1 3.2 4 Hydraulic PPE 4.1 4.2 4.3 5 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
10 Pressure and flow valves 10.1 10.2 10.3 10.4 10.5 10.6 11 Accumulators 11.1 11.2 11.3 12 Sensors 12.1 12.2 12.3 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 13.1 13.2 TOTAL Oil Transfer Hydraulic connections 30 min. 14 Oil and filters 14.1 14.2 14.3 14.4 14.5 TOTAL Oil Handling oil procedures/cleanliness Collecting an oil sample Check oil level Filters 30 min. 15 Pressure gauges/manometers 15.1 15.2 15.3 16 Symbols and Diagrams 16.1 16.2 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 18.1 18.2 18.3 GRAND TOTAL Summary Evaluation Certificates TOTAL TOTAL 60 min. 60 min. 30 min. 840 min. Page 25 / 111
1.9 Elements, BMT Hydraulics Module Lesson 1 Introduction ELEMENT 1.1 Safety instructions and emergency procedures 1.1.1 Safety instructions according to internal procedures 1.1.2 Emergency procedures and emergency exits in the localities the Delegates can be expected to be located during the course ELEMENT 1.2 Facilities 1.2.1 General description of the facilities on the location (Administration, dining area, restrooms and toilets, etc.) ELEMENT 1.3 Instructors shall give: Introduction 1.3.1 A short presentation of himself including his background as an instructor Delegates shall give: 1.3.2 A short introduction, including job function expectation for the course 1.3.3 The programme of the BMT Module, including breaks and meal times Page 26 / 111
ELEMENT 1.4 Scope and main objectives 1.4.1 Scope and main objectives of this BMT Module ELEMENT 1.5 On-going assessments 1.5.1 The reasons for the on-going assessment 1.5.2 GWO Control Measures and their use ELEMENT 1.6 Motivation 1.6.1 The importance of personal involvement in the course Lesson 2 Hydraulics introduction ELEMENT 2.1 The hydraulic system 2.1.1 Introduction to pressure 2.1.2 The typical components in a hydraulic system (e.g. pump, tank, hoses, valves) ELEMENT 2.2 Pascal s law 2.2.1 The basic concept regarding the incompressibility of fluid and how force can be transferred from one cylinder to another 2.2.2 Practical examples of Pascal s law Page 27 / 111
ELEMENT 2.3 Instructors shall lead discussion of: Transmission ratio 2.3.1 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: 3.1.1 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) 3.1.2 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: 3.2.1 The hazards caused by being exposed to hydraulic oil 3.2.2 The need of Material Safety Data Sheets (MSDS) Lesson 4 Hydraulic PPE ELEMENT 4.1 Types of PPE Instructors shall explain and demonstrate: 4.1.1 A glove suitable for hydraulic work 4.1.2 That not all gloves are suitable for hydraulic work 4.1.3 The consequence of not wearing the right PPE 4.1.4 Which goggles can be used for hydraulic work 4.1.5 The importance of wearing goggles when working with hydraulic systems Page 28 / 111
ELEMENT 4.2 proper inspections Instructors shall explain and demonstrate: 4.2.1 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: 4.3.1 How to choose the right PPE to wear for hydraulic work 4.3.2 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 5.1.1 The importance of Lock Out Tag Out 5.1.2 An example of the procedure for Lock Out Tag Out Delegates shall engage in discussions of: 5.1.3 Why it is important to prevent unexpected start-up Delegates shall practice and demonstrate: 5.1.4 An example of the procedure for Lock Out Tag Out Page 29 / 111
Lesson 6 Pumps ELEMENT 6.1 Gear pumps Instructors shall explain and demonstrate: 6.1.1 The parts of a gear pump 6.1.2 How a gear pump works 6.1.3 The symbol used in the diagram ELEMENT 6.2 Piston pumps Instructors shall explain and demonstrate: 6.2.1 The parts of a piston pump 6.2.2 How a piston pump works 6.2.3 The symbol used in the diagram ELEMENT 6.3 Pumps exercise Instructors shall explain and demonstrate: 6.3.1 The process to check the start and stop pressure on a pump Delegates are to practice and demonstrate: 6.3.2 How to check the start and stop pressure on a pump following the instructions from the trainer Lesson 7 Actuators ELEMENT 7.1 Types 7.1.1 The different types of actuators (e.g. cylinders and callipers) 7.1.2 The use of each type of actuator 7.1.3 The symbol for an actuator Page 30 / 111
ELEMENT 7.2 Hydraulic cylinders 7.2.1 Examples of faulty cylinders (e.g. pistons) 7.2.2 The hazards which may occur (e.g. causes of leaks and pressure drop) Lesson 8 Directional control valves ELEMENT 8.1 Types 8.1.1 The different types of directional valves (e.g. 2/3, 3/4) 8.1.2 The principle of operation of directional valves 8.1.3 That the directional control valve has been named based on how many ports and positions it has 8.1.4 That valves are shown de-energised in the diagram 8.1.5 The difference between an electrical operated valve and a pilot operated valve 8.1.6 The symbol for an electrical operated valve and pilot operated valve Delegates are to engage in discussions of: 8.1.7 The operation of directional valves Lesson 9 Proportional valves ELEMENT 9.1 Principle of operation 9.1.1 The use of proportional valves in a hydraulic circuit 9.1.2 The principle of operation of the proportional valves 9.1.3 The symbol for a proportional valve Delegates are to engage in discussions of: 9.1.4 The operation of a proportional valve in a circuit Page 31 / 111
Lesson 10 Pressure and flow valves ELEMENT 10.1 Pressure relief valves Instructors shall explain and demonstrate: 10.1.1 The function of the pressure relief valve and how it works 10.1.2 The position of a pressure relief valve in a circuit 10.1.3 How to check and adjust the pressure relief valve 10.1.4 The symbol for a pressure relief valve Delegates are to practice and demonstrate: 10.1.5 Checking and adjusting the pressure relief valve in a circuit ELEMENT 10.2 Pressure reduction valves Instructors shall explain and demonstrate: 10.2.1 The function of the pressure reduction valve and how it works 10.2.2 The position of a pressure reduction valve in a circuit 10.2.3 The symbol for a pressure reduction valve ELEMENT 10.3 Needle valves Instructors shall explain and demonstrate: 10.3.1 The function of the needle valve in a circuit 10.3.2 The position of a needle valve in a circuit 10.3.3 The symbol for a needle valve Delegates are to practice and demonstrate: 10.3.4 The operation of the needle valve in a circuit 10.3.5 The use of a needle valve to depressurize the hydraulic system Page 32 / 111
ELEMENT 10.4 Non return valves 10.4.1 The function of a non-return valve 10.4.2 The function of a pilot operated non-return valve 10.4.3 The position of a non-return valve in a circuit 10.4.4 The symbol for a non-return valve 10.4.5 The symbol for a pilot operated non-return valve ELEMENT 10.5 Throttle valves 10.5.1 The function of a throttle valve 10.5.2 The position of a throttle valve in a circuit 10.5.3 The symbol for a throttle valve ELEMENT 10.6 Orifice/restrictor valves 10.6.1 The function of an orifice/restrictor valve 10.6.2 The position of an orifice/restrictor valve in a circuit 10.6.3 The symbol for an orifice/restrictor valve Lesson 11 Accumulator ELEMENT 11.1 Use and types Instructors shall explain and demonstrate: 11.1.1 The different types of accumulators (bladder, piston and diaphragm) 11.1.2 The function of the accumulators in a circuit 11.1.3 The symbol for an accumulator Page 33 / 111
ELEMENT 11.2 Safety Instructors shall explain and demonstrate: 11.2.1 Principal characteristics of Nitrogen 11.2.2 Nitrogen bottles storage and handling requirements 11.2.3 The importance of discharging the accumulators prior to working on the system 11.2.4 The risks associated with a charged accumulator ELEMENT 11.3 Pre-charge pressure Instructors shall explain and demonstrate: 11.3.1 How to check the pre-charge pressure of an accumulator 11.3.2 The temperature correction chart Delegates shall practice and demonstrate: 11.3.3 How to check the pre-charge pressure of an accumulator 11.3.4 How to refill the accumulator Lesson 12 Sensors ELEMENT 12.1 Pressure sensors 12.1.1 The function of the pressure transducer and pressure switch 12.1.2 The position of the pressure transducer and pressure switch in a circuit 12.1.3 The symbol for a pressure transducer and pressure switch ELEMENT 12.2 Temperature sensors 12.2.1 The function of the temperature sensor 12.2.2 The position of the temperature sensor in a circuit 12.2.3 The symbol for a temperature sensor Page 34 / 111
ELEMENT 12.3 Flow sensors 12.3.1 The function of the flow sensor 12.3.2 The position of the flow sensor in a circuit 12.3.3 The symbol for a flow sensor Delegates shall engage in discussions of: 12.3.4 Different types, location and functions of sensors Lesson 13 Pipes, hoses and connections ELEMENT 13.1 Oil Transfer Instructors shall describe: 13.1.1 The function of hydraulic pipes and hoses 13.1.2 The position of the pipes and hoses in a circuit 13.1.3 The different types of pipes, hoses and fittings used in hydraulic systems 13.1.4 The symbol for a hose 13.1.5 The risks and hazards associated with pipes and hoses ELEMENT 13.2 Hydraulic connections Instructors shall describe: 13.2.1 How to make a connection with different fittings 13.2.2 The function of quick release couplings 13.2.3 The symbol for a quick release coupling Lesson 14 Oil and filters ELEMENT 14.1 Oil Instructors shall describe: 14.1.1 The characteristics of different types of oil Page 35 / 111
ELEMENT 14.2 Handling oil procedures/cleanliness Instructors shall describe: 14.2.1 The personal safety involved when handling oil 14.2.2 The environmental safety involved when handling oil 14.2.3 The importance of cleanliness ELEMENT 14.3 Collecting an oil sample Instructors shall describe: 14.3.1 The importance of collecting an oil sample ELEMENT 14.4 Checking oil level Instructors shall explain and demonstrate: 14.4.1 The function of the tank 14.4.2 Oil level checking with a dip stick 14.4.3 Oil level checking with a sight glass 14.4.4 Oil level checking with a filling hole Delegates shall practice and demonstrate: 14.4.5 The procedures for checking oil level with a dip stick, sight glass and filling hole ELEMENT 14.5 Filters Instructors shall describe: 14.5.1 The function of the filters 14.5.2 The different types of filters 14.5.3 The particle sizes 14.5.4 The importance of replacing filters 14.5.5 The symbol for filters 14.5.6 The position of filters in a circuit Page 36 / 111
Lesson 15 Pressure gauges/manometers ELEMENT 15.1 Pressure gauge/manometer characteristics Instructors shall explain and demonstrate: 15.1.1 The characteristic of pressure gauges/manometers 15.1.2 The symbol for a pressure gauge/manometer Delegates shall engage in discussions of: 15.1.3 How to use a pressure gauge/manometer ELEMENT 15.2 Checking calibration Instructors shall demonstrate: 15.2.1 How to check that a pressure gauge is calibrated Delegates are to practice and demonstrate: 15.2.2 Checking the calibration of pressure gauges ELEMENT 15.3 Pressure measuring Instructors shall demonstrate: 15.3.1 How to take an accurate pressure measurement Delegates are to practice and demonstrate: 15.3.2 How to measure the hydraulic pressure accurately Page 37 / 111
Lesson 16 Symbols and diagrams ELEMENT 16.1 Main symbols and components Instructors shall summarise: 16.1.1 The symbols that represent each components of a hydraulic circuit 16.1.2 The symbols of the main elements in a diagram ELEMENT 16.2 Identifying measuring points 16.2.1 The accurate measuring points in a circuit 16.2.2 The symbol of measuring points Delegates shall engage in discussions of: 16.2.3 Hydraulic systems and the symbols used in hydraulic circuit diagrams 16.2.4 Identifying accurate measuring points using a diagram Lesson 17 Hydraulic theory test ELEMENT 17.1 Test Instructors shall: 17.1.1 Conduct the test with the delegates Delegates shall: 17.1.2 Conduct the test within 30 minutes Instructors shall: 17.1.3 Check the test results and give feedback to the Delegates about the test result Page 38 / 111
Lesson 18 Evaluation ELEMENT 18.1 Summary Instructors shall: 18.1.1 Summarise the BMT Module and give the Delegates final feedback ELEMENT 18.2 Evaluation Delegates shall: 18.2.1 Conduct a written evaluation Instructors shall: 18.2.2 Give necessary feedback on the written evaluations ELEMENT 18.3 Certificates Instructors shall: 18.3.1 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
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
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
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
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
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
Demonstrates understanding of subject Total Marks 0 9 Pass 10 27 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
GLOBAL WIND ORGANISATION STANDARD Basic Maintenance Training (BMT) (Onshore/Offshore) MECHANICAL MODULE Version 0 21 March, 2016 Page 46 / 111
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
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
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
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
Lesson 3 165 min. The principles of bolted and welded connections The aim of this lesson is to give Delegates an understanding of threads and bolted connections and their maintenance. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the principles of threaded components (2) Explain the location of important bolted and welded connections and explain the importance of maintaining bolted connections (3) Explain the hazards and risks associated with maintaining bolted and welded connections (4) Explain how a damaged weld is recognised (5) Explain other damage by visual inspection (paint damage, corrosion, leaks and cracks) Lesson 4 120 min. Use of tools and measuring equipment for wind turbine maintenance The aim of this lesson is to give the Delegates the needed knowledge and practical skills to use specific tools for wind turbine maintenance. To successfully complete this BMT Module, Delegates shall be able to: (1) Demonstrate how to select and use the correct spanners for bolted connections (2) Demonstrate how to select and use the correct screw drivers for screwed connections (3) Demonstrate how to adjust and use a torque wrench (4) Demonstrate how to measure gaps between components using feeler gauges (5) Demonstrate how to take measurements using a calliper (6) Demonstrate how to check the run out of a disc using a dial gauge (7) Explain what a laser alignment tool is used for Page 51 / 111
Lesson 5 45 min. Gearbox The aim of this lesson is to give the Delegates the needed knowledge and understanding about the gearbox and the bearings to include types, functional design, visual inspection, damage and basic maintenance routines. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the main function and operating principles of the gearbox (2) Explain the risks and hazards associated with the gearbox and coupling (3) Explain how to check hoses and seals and explain the importance of the right oil level and taking an oil sample Lesson 6 90 min. Braking system and coupling The aim of this lesson is to give Delegates the needed knowledge and understanding of the coupling and the two braking systems in a wind turbine. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the main task and function of the disc brake and the aerodynamic brake (2) Explain the task and the function of the coupling (3) Explain the dangers of working on the braking system and know how to minimise them. Use safe working practices and appropriate PPE to safeguard themselves, others and to protect the environment (4) Demonstrate how to perform the inspection of the brake system (a visual inspection of disc surface and brake pads) Page 52 / 111
Lesson 7 60 min. Yaw system The aim of this lesson is to give the Delegates the needed knowledge and understanding of the yaw system and the sensors which influence the system. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the function of the yaw system (2) Explain the components and their functions (yaw gear, motors, yaw bearing, wind sensor, anti-twist protection, slide bearing, lubrication system) (3) Explain the dangers of working on the yawing system and know how to minimise them. Use safe working practices and appropriate PPE to safeguard themselves, others and to protect the environment Lesson 8 180 min. Cooling- and lubrication system The aim of this lesson is to give the Delegates the needed knowledge and understanding of the lubrication and cooling system. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain which components in a WTG have to be cooled and why (2) Explain the single components of the cooling system and how they are connected to each other (3) Explain the single components of the lubrication system and explain which parts need to have oil levels maintained and why (4) Explain how a mal-functioning or damaged cooling / lubrication system influences other parts of a WTG (5) Explain the dangers of working on the cooling/heating system and know how to minimise them. Explain the use safe working practices and appropriate PPE to safeguard themselves, others and to protect the environment (6) Demonstrate how to perform a visual inspection of the cooling and/or lubrication system (7) Recognise damaged parts and understand the need for its documentation Page 53 / 111
Lesson 9 60 min. Mechanical Theory Test The aim of this lesson is to test the Delegates theoretical knowledge of mechanical systems, and to discuss the result of the test with the Delegates Lesson 10 Evaluation 15 min. The aim of this lesson is to summarize this 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 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) Correct use of appropriate PPE (2) Safe working procedures for mechanical work (3) Correct and proper methods of working with mechanical systems The formal evaluation of knowledge of above scenarios shall be in accordance with the Control Measures in Section 3 (Measures). Page 54 / 111
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 55 / 111
1.8 BMT Mechanical Module Time Table The order in which the elements of the Training Module are delivered may vary. Lesson 1 Introduction 1.1 2 Mechanical introduction 1.2 1.3 1.4 1.5 1.6 2.1 2.2 2.3 2.4 Element Safety instructions and emergency procedures Facilities Introduction Scope and main objectives On-going assessment Motivation TOTAL Main components of the structure Main mechanical systems How a turbine works and the physics involved Risks and Hazards on mechanical systems Approximate Duration 15 min. 3 The principles of bolted and welded connections 4 Use of tools and measuring equipment for wind turbine maintenance 3.1 3.2 3.3 3.4 3.5 4.1 4.2 4.3 4.4 4.5 TOTAL The principles of threaded components The locations of important bolted and welded connections The inspection of welded joints Checking bolt connections and correct tightening tools Recognise damage by visual inspection TOTAL Selecting and using the correct spanners for bolted connections Selecting and using the correct screw drivers for screwed connections Correctly setting and using a torque wrench Accurately gauging gaps between components Callipers 90 min. 165 min. Page 56 / 111
4.6 Checking the run out of a disc and using a dial indicator 4.7 Introduction to the laser alignment tool TOTAL 5 Gearbox 5.1 The function and operating principles 5.2 Hazards and risks associated with the gearbox and coupling 5.3 Inspections TOTAL 6 Braking system and 6.1 The function of the disc and coupling the aerodynamic brake 6.2 The function of the coupling 6.3 Hazards and risks associated with the brake system 6.4 Inspection of the braking system TOTAL 7 Yaw System 7.1 The function of the Yaw system 7.2 The components of the Yaw system and their functions 7.3 Hazards and risks associated with the Yaw system TOTAL 8 Cooling and 8.1 Components requiring cooling Lubrication System and why 8.2 Interconnection of individual components 8.3 Components of the lubrication and maintenance of levels 8.4 The effects of malfunctions on the operation of the turbine systems 8.5 Hazards and risks associated with the lubrication and cooling systems 8.6 Inspection of the lubrication and cooling systems 8.7 Recognizing damage and completing the documentation TOTAL 9 Mechanical Theory 9.1 Test Test TOTAL 120 min. 45 min. 90 min. 60 min. 180 min. 60 min. Page 57 / 111
10 Evaluation 10.1 10.2 10.3 GRAND TOTAL Summary Evaluation Certificates TOTAL 15 min. 840 min. 1.9 Elements, BMT Mechanical Module Lesson 1 Introduction ELEMENT 1.1 Safety instructions and emergency procedures 1.1.1 Safety instructions according to internal procedures 1.1.2 Emergency procedures and emergency exits in the localities the Delegates can be expected to be located during the course ELEMENT 1.2 Facilities 1.2.1 General description of the facilities on the location (Administration, dining area, restrooms, toilets, etc.) ELEMENT 1.3 Introduction Instructors shall give: 1.3.1 A short presentation of himself including his background as an instructor Delegates shall give: 1.3.2 A short introduction, including job function expectation for the course 1.3.3 The programme of the BMT Module, including breaks and meal times Page 58 / 111
ELEMENT 1.4 Scope and main objectives 1.4.1 Scope and main objectives of this BMT Module ELEMENT 1.5 On-going assessments 1.5.1 The reasons for the on-going assessment 1.5.2 GWO Control Measures and their use ELEMENT 1.6 Motivation 1.6.1 The importance of personal involvement in the course Lesson 2 Mechanical Introduction ELEMENT 2.1 Main components of the structure 2.1.1 The location of the: (1) Foundation (2) Transition piece (3) Tower sections (4) Nacelle (5) Rotor and blades (6) Platforms, ladders and lift Delegates shall engage in discussions of: 2.1.2 The construction components of a wind turbine Page 59 / 111
ELEMENT 2.2 Main mechanical systems 2.2.1 The basic function and location of the: (1) Pitch system (2) Yaw system (3) Drive train (4) Gearbox (5) Coupling (6) Generator Delegates shall engage in discussions of: 2.2.2 The basic mechanical systems in a wind turbine ELEMENT 2.3 How a turbine works and the physics involved 2.3.1 Energy changing from linear to rotational motion and to electrical energy 2.3.2 Wind speed/velocity and direction 2.3.3 The basic aerodynamics of the blade 2.3.4 Control of the rotor speed using the pitch system Delegates shall engage in discussions of: 2.3.5 Energy, wind speed and wind direction ELEMENT 2.4 Risks and Hazards on mechanical systems 2.4.1 The safety risks and hazards in mechanical systems (e.g. bruises, squeezing, rotation, fluids, trapping, slipping, pinching) 2.4.2 The importance of working according to approved working practices 2.4.3 The PPE requirements for working on mechanical systems 2.4.4 The need for Material Safety Data Sheets (MSDS) Delegates shall engage in discussions of: Page 60 / 111
2.4.5 Safe working procedures, identifying the necessary PPE and appropriate tools Lesson 3 The principles of bolted and welded connections ELEMENT 3.1 The principles of threaded components 3.1.1 The meaning of pitch of a thread 3.1.2 The angle of a thread 3.1.3 The outside and core diameters of threads 3.1.4 Right and left hand threads 3.1.5 Strength proportional to size of the bolt 3.1.6 Strength due to material 3.1.7 Function and types of washers 3.1.8 Force x length with reference to spanners. 3.1.9 Importance of correct torque (e.g. collapsing towers, electrical fires) 3.1.10 Lubrication 3.1.11 That bolts and nuts need the same temperature 3.1.12 The difference between torque and tension 3.1.13 The principles of angular tightening Delegates shall engage in discussions of: 3.1.14 Bolts, threads, strengths of materials and temperature influences 3.1.15 Force and torque Page 61 / 111
ELEMENT 3.2 The locations of important bolted and welded connections 3.2.1 Connection between tower and transition piece 3.2.2 Connections between sections of the tower 3.2.3 Platforms in the tower 3.2.4 Ladders in the tower 3.2.5 Guard rails on the transition piece 3.2.6 An example of a bolted connection and a welded connection 3.2.6 Bolted connections holding cranes 3.2.7 Bolted connections with the Fall Arrester system 3.2.8 Bolted connections on the rotor, coupling, gearbox and generator Delegates shall engage in discussions of: 3.2.9 Importance of maintenance and maintenance processes for bolted connections ELEMENT 3.3 The inspection of welded joints 3.3.1 What a good weld is and how to recognise it 3.3.2 What a damaged weld is and how to recognise it 3.3.3 How to clean a suspect weld using sand paper and use a dye penetrant spray to check it 3.3.4 The importance of using documentation in the event of identifying a damaged welded joint ELEMENT 3.4 Checking bolt connections and correct tightening tools 3.4.1 How to check if a bolt is loose 3.4.2 What the correct tool is for tightening bolts Page 62 / 111
ELEMENT 3.5 Recognise damage by visual inspection 3.5.1 How to recognise paint damage 3.5.2 How to recognise corrosion 3.5.3 How to recognise cracks 3.5.4 How to recognise leaks Delegates shall engage in discussions of: 3.5.5 Recognition of damage, corrosion and leaks of bolted or welded connections and the consequences of not repairing them Lesson 4 Use of tools and measuring equipment for wind turbine maintenance ELEMENT 4.1 Instructors shall explain and demonstrate: Selecting and using the correct spanners for bolted connections 4.1.1 Types of spanners 4.1.2 Correct application of spanner types 4.1.3 Use of correct size of spanner 4.1.4 Consequences of incorrect spanner use Delegates shall practice and demonstrate: 4.1.5 Selecting and using spanners ELEMENT 4.2 Instructors shall explain and demonstrate: Selecting and using the correct screw drivers for screwed connections 4.2.1 Types of screw drivers 4.2.2 Correct application of screw driver type 4.2.3 Consequences of incorrect use Page 63 / 111
Delegates shall practice and demonstrate: 4.2.4 Selecting and using screw drivers ELEMENT 4.3 Instructors shall explain and demonstrate: Correctly setting and using a torque wrench 4.3.1 How to use the torque wrench 4.3.2 The importance of checking calibration Delegates shall practice and demonstrate: 4.3.3 Setting and using torque wrenches ELEMENT 4.4 Instructors shall explain and demonstrate: Accurately gauging gaps between components 4.4.1 How to use feeler gauges 4.4.2 How to care for feeler gauges to prevent damage Delegates shall practice and demonstrate: 4.4.3 Correct use and care of feeler gauges ELEMENT 4.5 Callipers Instructors shall explain and demonstrate: 4.5.1 How to care for callipers 4.5.2 How to take measurements using callipers Delegates shall practice and demonstrate: 4.5.3 Measuring thicknesses, internal diameters and depth using a calliper Page 64 / 111
ELEMENT 4.6 Instructors shall explain and demonstrate: Checking the run out of a disc and using a dial indicator 4.6.1 How to use a dial indicator 4.6.2 How to check the run out of a disc using a dial indicator Delegates shall practice and demonstrate: 4.6.3 Using a dial indicator ELEMENT 4.7 Introduction to the laser alignment tool 4.7.1 What a laser alignment tool can be used for Lesson 5 Gearbox ELEMENT 5.1 The function and operating principles 5.1.1 The main function of the gearbox 5.1.2 The operation of the gearbox ELEMENT 5.2 Risks and hazards associated with the gearbox and coupling 5.2.2 The importance of locking the system so that it cannot turn (LOTO) 5.2.2 The hazards associated with gearbox oil 5.2.3 The correct PPE Page 65 / 111
ELEMENT 5.3 Inspections 5.3.1 Checking hoses, what to look for 5.3.2 Checking seals, what to look for 5.3.3 The importance of the right oil level 5.3.4 The importance of taking oil sample Lesson 6 Braking system and coupling ELEMENT 6.1 The function of the disc and the aerodynamic brake 6.1.1 The purpose of the disc brake 6.1.2 The purpose of the aerodynamic brake 6.1.3 The consequences of it not functioning 6.1.4 The operating principle of the disc brake 6.1.5 The operating principle of the aerodynamic brake ELEMENT 6.2 The function of the coupling 6.2.1 The function of the coupling ELEMENT 6.3 Risks and hazards associated with the brake system 6.3.1 The necessity for LOTO (e.g. risk of moving parts, pressurized systems) 6.3.2 The correct PPE associated with the brake system Page 66 / 111
ELEMENT 6.4 Inspection of the braking system 6.4.1 How to check the disc surface for wear and scuffing due to excess friction 6.4.2 How to check the disc brake pads for wear Delegates shall practice and demonstrate: 6.4.3 Checking the thickness of the brake pads. 6.4.4 Measuring thickness of disc Lesson 7 Yaw system ELEMENT 7.1 The function of the Yaw system 7.1.1 The function of the yaw system ELEMENT 7.2 The components of the yaw system and their functions 7.2.1 The yaw gear and its function 7.2.2 The yaw gear motors and their function 7.2.3 The wind sensor and its function 7.2.4 The anti-twist protection mechanism 7.2.5 The lubrication system 7.2.6 The yaw ball bearing and sliding bearing system Page 67 / 111
ELEMENT 7.3 Risks and hazards associated with the yaw system 7.3.1 The importance of LOTO Delegates shall engage in discussions of: 7.3.2 The dangers connected with the yaw system and how to minimise them Lesson 8 Cooling and lubrication system ELEMENT 8.1 Components that require cooling and why 8.1.1 How heat is produced by turning the gearbox 8.1.2 How heat is produced in the generator 8.1.3 How heat is produced by pressurising the hydraulic system 8.1.4 How overheating can make the machines become inefficient 8.1.5 How failure to control the temperature can result in failure of the system ELEMENT 8.2 Interconnection of individual components 8.2.1 That all the components of the turbine are reliant on each other 8.2.2 That heat can be transferred from component to component 8.2.3 That expansion due to heat can cause failure of the system Page 68 / 111
ELEMENT 8.3 Components of the lubrication and the maintenance of levels 8.3.1 How oil and grease reduces friction and lowers the production of heat 8.3.2 How oil is pumped around the gearbox to keep the temperature down 8.3.3 The use of heat exchangers and radiators to reduce the heat in a system 8.3.4 That some systems have a cooling system that employs a cooling liquid in a discrete circuit 8.3.5 That oil and grease pumps can be used to keep the bearings, yaw and pitch systems lubricated to reduce friction and corrosion 8.3.6 The importance of maintaining the correct levels in the systems 8.3.7 How to check what the correct oil or grease is for a specific application ELEMENT 8.4 The effects of malfunctions on the operation of the turbine systems 8.4.1 The consequences of a gearbox failure 8.4.2 The consequences of a pitch system failure 8.4.3 The consequences of a yaw system failure 8.4.4 The consequences of the generator overheating Delegates shall engage in discussions of: 8.4.5 Consequences of not using the appropriate oil or grease ELEMENT 8.5 Risks and hazards associated with the lubrication and cooling systems Instructors are to explain: 8.5.1 Hazards of pressurised systems 8.5.2 Hazards of hot components 8.5.3 Hazards of oils and greases 8.5.4 The use of PPE Page 69 / 111
8.5.5 Correct procedure for the disposal of waste oils and greases Delegates shall engage in discussions of: 8.5.6 The personal and environmental consequences of not following approved working procedures and safe working practices ELEMENT 8.6 Inspection of the lubrication and cooling systems 8.6.1 How to visually check hoses for damage (e.g. pin holes, cracks, cuts, friction marks, leaks) 8.6.2 How to visually check fittings for leaks 8.6.3 The importance of checking the cooling liquid 8.6.4 The importance of oil inspection (e.g. level, oil sample) 8.6.5 How to check the cleanliness of the heat exchanger and coolant pipes Delegates shall engage in discussions of: 8.6.6 Oil Cleanliness rating and its impact on component performance Delegates shall practice and demonstrate: 8.6.7 Correct use of PPE and working procedures for inspecting cooling and lubrication systems 8.6.8 Visual inspection of cooling and/or lubricating systems ELEMENT 8.7 Recognising damage and completing documentation 8.7.1 What damage to look for on hoses 8.7.2 What damage to look for on fittings, washers and seals 8.7.3 What damage to look for on heat exchangers 8.7.4 The importance of documenting any damage found Page 70 / 111
Lesson 9 ELEMENT 9.1 Instructors shall: Mechanical theory test Test 9.1.1 Conduct the test with the delegates Delegates shall: 9.1.2 Conduct the test within 30 minutes Instructors shall: 9.1.3 Check the test results and give feedback to the Delegates about the test result Lesson 10 Evaluation ELEMENT 10.1 Summary Instructors shall: 10.1.1 Summarise the BMT Module and give the Delegates final feedback ELEMENT 10.2 Evaluation Delegates shall: 10.2.1 Conduct a written evaluation Instructors shall: 10.2.2 Give necessary feedback on the written evaluations Notes: The module 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. Page 71 / 111
Section 2 Resources for BMT Mechanical The Training Provider shall ensure that staff, 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 instructors 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 Mechanical Module Practical 1:6 Page 72 / 111
2.3 Facilities The full range of facilities shall be available during the training. The following facility criteria shall be adhered to. 2.4 Theory 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. 2.6 Equipment The following equipment is required during the entire duration of this BMT Mechanical Training to meet the needs of the BMT Mechanical Module (1) PPE suitable for mechanical work (2) Spanners (3) Screwdrivers (4) Torque wrenches (5) Hexagon (Allen) keys Page 73 / 111
(6) Feeler gauges (7) Dial gauge (8) Vernier or Digital Callipers (9) Dial Type Indicators (10) Brake disc (11) Brake pad (12) Mock up for bolt torque including various sets of bolts 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 74 / 111
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 Mechanical 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 Mechanical Module. 3.4 Control Measures Please find the Control Measures Form on next page. Page 75 / 111
Control Measure Name: Course: BMT Mechanical 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 maintained 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 Page 76 / 111
Applies subject knowledge correctly in given scenario Demonstrates understanding of subject Total Marks 0 9 Pass 10 27 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 77 / 111
GLOBAL WIND ORGANISATION STANDARD Basic Maintenance Training (BMT) (Onshore/Offshore) ELECTRICAL MODULE Version 0 21 March, 2016 Page 78 / 111
Module 3 - The BMT Electrical Module 1.1 Duration of the BMT Electrical Module The optimal total time for completing this BMT Electrical Module is minimum 20 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 program 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. Page 79 / 111
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 basic Electrical Training Module is targeted at personnel with little or no previous experience of electrical systems. It will give them the basic skills and knowledge to carry out basic maintenance tasks using safe working procedures and the correct PPE. 1.3 Delegate prerequisites for the BMT Electrical 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 Electrical 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 80 / 111
1.5 Aims and objectives of the BMT Electrical Module The aim of this BMT Module is to give the Delegates the knowledge and skills to carry out basic electrical maintenance tasks (supervised by an experienced technician), using safe working procedures and the correct PPE. The BMT Electrical Module shall ensure that: (1) The Delegates are able to explain a simple electrical system and the symbols used in a simple electrical circuit diagram. They will be able to interpret these diagrams and explain several electrical components (2) The Delegates are able to demonstrate how to measure current, voltage, resistance and perform continuity test. (3) The Delegates are able to explain the electrical hazards in a WTG (4) The Delegates are able to explain examples of electrical PPE and tools and demonstrate how to inspect them before use. (5) The Delegate will be able to explain the importance of Lock Out Tag Out and demonstrate the principles involved. (6) The Delegate will be able to explain the function of resistors, switches, relays, contactors, diodes, bridge rectifiers, capacitors, transformers, generators, electrical protections, batteries and processor control system (7) The Delegate will be able to explain different sensors used in a WTG and their position and function. Page 81 / 111
1.6 Learning outcomes of the BMT Electrical Module The learning outcomes specified for the Basic Electric 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 90 min. Introduction to electricity The aim of this lesson is to give the Delegates the needed knowledge and understanding about basic electrical systems. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the units of electrical magnitude. (2) Explain the fundamentals of Ohm s Law and be able to carry out exercises using the formula (3) Explain the role of appointed (authorized) persons Page 82 / 111
Lesson 3 60 min. Alternating current introduction The aim of this lesson is to give the Delegates the needed knowledge and understanding of alternating current and electrical theory. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the principles of alternating current (2) Interpret a basic circuit diagram (3) Distinguish between AC and DC Lesson 4 90 min. Electrical measuring instruments The aim of this lesson is to give the Delegates the needed knowledge and understanding of the correct and safe use of measuring equipment. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the symbols and settings used for current, voltage and resistance in the multimeter and the amp clamp meter. (2) Demonstrate how to use a multimeter in the correct way to measure current, voltage and resistance and to carry out a continuity test (3) Demonstrate how to use an amp clamp meter in the correct way to measure current Page 83 / 111
Lesson 5 120 min. Electrical hazards The aim of this lesson is to give the Delegates the needed knowledge and understanding of the electrical hazards in a WTG. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the effect on the body of an electrical contact (2) Explain direct and indirect contact situations (3) Explain hazards related to cables in a wind turbine (4) Explain hazards related to high voltage (5) Explain the electrical hazards related to the busbars (6) Explain protective earth (7) Explain the risks associated with stored energy (8) Explain static electricity as a hazard Lesson 6 15 min. Safety signs The aim of this lesson is to give the Delegates the needed knowledge and the skills to understand safety signs. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the meaning of safety signs Page 84 / 111
Lesson 7 45 min. Personal protective equipment and tools The aim of this lesson is to give the Delegates an understanding of PPE and tools for working with electricity in a WTG, their correct use and demonstrate how to inspect them before use. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain examples of PPE and demonstrate how to make a proper inspection of it (2) Explain examples of tools appropriate for electrical work and how to inspect them Lesson 8 45 min. Prevention of unexpected start-up The aim of this lesson is to make the Delegates able to understand the importance of Lock Out Tag Out procedures and demonstrate the principles involved. To successfully complete this BMT 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 85 / 111
Lesson 9 165 min. Components and symbols The aim of this lesson is to give the Delegates the needed knowledge and understanding of electrical and electronic components. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the function of the resistor (2) Explain the function of the batteries (3) Explain the function of the switches (4) Explain the function of the contactors (5) Explain the function of the relays (6) Explain the function of the diodes (7) Explain the function of the bridge rectifiers (8) Explain the function of the capacitor (9) Demonstrate how to check a diode and a bridge rectifier (10) Demonstrate how to check a capacitor (11) Explain the function of transformers (12) Explain the function of generators and motors (13) Explain the function of fuses and circuit breakers (14) Explain the function of the processor control system Lesson 10 225 min. Sensors The aim of this lesson is to give the Delegates the needed knowledge and understanding to of the different sensors in an electric circuit. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain the different types of sensors and their symbols (2) Explain the function of the wind sensors (3) Explain the function of a temperature sensor and test it (4) Explain the function of a yaw sensor (5) Explain the function of a pressure sensor Page 86 / 111
Lesson 11 Electrical circuits 75 min. The aim of this lesson is to give the Delegates the needed knowledge and understanding of simple electrical circuits and enable the delegates to apply that knowledge to interpret a simple electrical diagram. To successfully complete this BMT Module, Delegates shall be able to: (1) Explain components of an electric circuit in a diagram (2) Demonstrate how to interpret basic electrical diagrams (3) Demonstrate how to assemble a simple electric circuit (4) Explain how to choose a measuring point of an installation in the diagram and in the electric circuit (5) Explain the main electrical systems in a WTG Lesson 12 60 min. Electric Theory Test The aim of this lesson is to test the Delegates theoretical knowledge of electric systems, and to discuss the result of the test with the Delegates. Lesson 13 30 min. Evaluation The aim of this lesson is to summarize this 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 87 / 111
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) Correct use of appropriate PPE (2) Safe working procedures for mechanical work (3) Correct and proper methods of working with mechanical 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 88 / 111
1.8 BMT Electric Module Time Table The order in which the elements of the Training Module are delivered may vary. Lesson 1 Introduction 1.1 2 Introduction to Electricity 1.2 1.3 1.4 1.5 1.6 2.1 2.2 2.3 Element Safety instructions and emergency procedures Facilities Introduction Scope and main objectives On-going assessment Motivation TOTAL Direct current Ohm s Law Appointed persons Approximate Duration 30 min. 3 Alternating current introduction 4 Electrical measuring instruments 3.1 3.2 3.3 4.1 4.2 5 Electrical hazards 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 6 Safety signs 6.1 Safety signs 7 Personal Protective equipment and tools 8 Prevention of unexpected start-up TOTAL Alternating current Alternating current in the Circuit diagram Alternating current/direct current TOTAL Symbols and settings on the multimeter and the Amp Clamp Meter Digital instrument/multimeter TOTAL Effect of the electric current Direct and indirect contacts Damaged cables High voltage Busbars PE and GFCI/RCD Stored energy Static electricity TOTAL TOTAL 7.1 Types of PPE 7.2 Types of tools and instruments TOTAL 8.1 The importance of Lock Out Tag Out 90 min. 60 min. 90 min. 120 min. 15 min. 45 min. Page 89 / 111
9 Components, symbols and diagrams 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 10 Sensors 10.1 10.2 10.3 10.4 10.5 11 Electrical circuits 11.1 11.2 11.3 11.4 TOTAL Resistors Batteries Switches Contractors Relays Diodes Bridge rectifiers Capacitors Transformers Generators and motors Fuses and circuit breakers Process control systems TOTAL Types Wind sensors Temperatures Yaw sensors Pressure sensors TOTAL Symbols and diagrams Assembly of an electrical circuit Measuring points The electrical WTG system 45 min. 165 min. 225 min. 12 Electric Theory Test 12.1 Test 13 Evaluation 13.1 13.2 13.3 GRAND TOTAL Summary Evaluation Certificates TOTAL TOTAL TOTAL 75 min. 60 min. 30 min. 1050 min. Page 90 / 111
1.9 Elements, BMT Electric Module Lesson 1 Introduction ELEMENT 1.1 Safety instructions and emergency procedures 1.1.1 Safety instructions according to internal procedures 1.1.2 Emergency procedures and emergency exits in the localities the Delegates can be expected to be located during the course ELEMENT 1.2 Facilities 1.2.1 General description of the facilities on the location (Administration, dining area, restrooms, toilets, etc.) ELEMENT 1.3 Instructors shall give: Introduction 1.3.1 A short presentation of himself including his background as an instructor Delegates shall give: 1.3.2 A short introduction, including job function expectation for the course 1.3.3 The programme of the BMT Module, including breaks and meal times ELEMENT 1.4 Scope and main objectives 1.4.1 Scope and main objectives of this BMT Module Page 91 / 111
ELEMENT 1.5 On-going assessments 1.5.1 The reasons for the on-going assessment 1.5.2 GWO Control Measures and their use ELEMENT 1.6 Motivation 1.6.1 The importance of personal involvement in the course Lesson 2 Introduction to electricity ELEMENT 2.1 Direct current 2.1.1 Electrical current definition and units 2.1.2 The basic concept between the current flow and the resistance 2.1.3 Voltage definition and units 2.1.4 Resistance definition and units. Variable resistance (PT100-temp) ELEMENT 2.2 Ohm s Law 2.2.1 Practical examples of Ohm s Law using a simple circuit diagram of battery and resistor Delegates shall engage in discussions of: 2.2.2 Relationship between current, voltage and resistance Delegates shall apply: 2.2.3 Ohm s Law exercises Page 92 / 111
ELEMENT 2.3 Appointed Persons 2.3.1 Why it is important, that only instructed and appointed persons are allowed to perform electrical work 2.3.2 This course will not make the Delegate an appointed (authorised) or instructed persons Lesson 3 Alternating current introduction ELEMENT 3.1 Alternating current 3.1.1 The theory behind alternating current ELEMENT 3.2 Alternating current in the circuit diagram 3.2.1 The location of AC in a basic electrical circuit diagram ELEMENT 3.3 Alternating current/direct current 3.3.1 Difference between alternating and direct current. Page 93 / 111
Lesson 4 Electrical measuring instruments ELEMENT 4.1 Instructors shall explain and demonstrate: Symbols and settings on the Multimeter and the Amp Clamp meter 4.1.1 Settings on the Multimeter including: (1) VAC and VDC (2) A and ma (3) Ohms/ continuity 4.1.2 Settings on the Amp Clamp meter including: (1) A and ma Delegates shall demonstrate: 4.1.3 How to measure amp with Amp clamp meter ELEMENT 4.2 Instructors shall explain and demonstrate: Digital instrument/multimeter 4.2.1 The measurement of (1) VAC and VDC (2) A and ma (3) Ohms/ continuity Delegates shall demonstrate: 4.2.2 How to measure Volt, Amp and resistance using a multimeter 4.2.2 How to measure continuity using a multimeter Page 94 / 111
Lesson 5 Electrical hazards ELEMENT 5.1 Effect of the electric current 5.1.1 The effects on the body due to contact with electricity Delegates shall engage in discussions of: 5.1.2 The relation between current and contact time ELEMENT 5.2 Direct and indirect contacts 5.2.1 When and how a direct contact happens 5.2.2 When and how an indirect contact happens Delegates shall explain: 5.2.3 Some examples of direct contact 5.2.4 Some examples of indirect contact ELEMENT 5.3 Damaged cables 5.3.1 Examples of reliable and damaged cables Delegates shall engage in discussions of: 5.3.2 Different hazards, which can arise from damaged cables Page 95 / 111
ELEMENT 5.4 High voltage 5.4.1 The definition of high voltage (dependent on the country) 5.4.2 The possible hazards related to high voltage 5.4.3 Different examples of possible hazards (high voltage transformer, switchgear) Delegates shall engage in discussions of: 5.4.4 Awareness of high voltage ELEMENT 5.5 Busbars 5.5.1 The possible hazards related to busbars Delegates shall engage in discussions of: 5.5.2 The possible hazards related to busbars ELEMENT 5.6 PE and GFCI/RCD Instructors shall explain and illustrate: 5.6.1 The function and importance of protective earth 5.6.2 The function of the GFCI/RCD 5.6.3 The symbol of the GFCI/RCD ELEMENT 5.7 Stored energy 5.7.1 The risks related to (1) The UPS system e.g. risk of back feed (2) Capacitors e.g. risk of stored energy and arc flash (3) Batteries e.g. risk of stored energy and arc flash Page 96 / 111
ELEMENT 5.8 Static electricity 5.8.1 The danger of static electricity in connection with the blade Lesson 6 Safety signs ELEMENT 6.1 Safety signs 6.1.1 The meaning of the different safety signs 6.1.2 Show examples of safety signs on different locations in the WTG Delegates shall engage in discussion of: 6.1.3 Different safety signs meanings Lesson 7 Personal protective equipment and tools ELEMENT 7.1 Types of PPE Instructors are to explain and demonstrate: 7.1.1 Examples of usage and the inspection of PPE suitable for electrical work Delegates shall practice and demonstrate: 7.1.2 The inspection of gloves Page 97 / 111
ELEMENT 7.2 Instructors are to explain: Types of tools and instruments 7.2.1 How to recognise tools suitable for electrical work (e.g. insulated tools) 7.2.2 Test instruments, leads and their categories 7.2.3 Calibration and visual inspection of test instruments and leads Delegates shall engage in discussion of: 7.2.4 How to identify the validity of tools Lesson 8 Prevention of un-expected start up ELEMENT 8.1 Instructors are to explain: The importance of Lock Out Tag Out 8.1.1 The importance of Lock Out Tag Out 8.1.2 An example of the procedure for Lock Out Tag Out Delegates shall engage in discussions of: 8.1.3 Why it is important to prevent unexpected start-up Delegates shall practice and demonstrate: 8.1.4 An example of the procedure for Lock Out Tag Out Lesson 9 Components and symbols ELEMENT 9.1 Instructors are to explain: Resistors 9.1.1 The function of resistors 9.1.2 The symbol for resistors 9.1.3 The position of resistors in a circuit Page 98 / 111
ELEMENT 9.2 Instructors are to explain: Batteries 9.2.1 The function of batteries 9.2.2 The symbol for batteries 9.2.3 The position of batteries in a circuit 9.2.4 The risks and hazards associated with stored energy ELEMENT 9.3 Switches 9.3.1 The function of switches 9.2.3 The symbols for different switches 9.3.3 The position of switches in a circuit ELEMENT 9.4 Contactors 9.4.1 Different contactors 9.4.2 The function of contactors 9.4.3 The symbol for contactors 9.4.4 The position of contactors in a circuit ELEMENT 9.5 Relays Instructors shall explain and demonstrate: 9.5.1 Different relays 9.5.2 The function of relays 9.5.3 The symbol for relays 9.5.4 The position of relays in a circuit ELEMENT 9.6 Diodes Instructors shall explain and demonstrate: 9.6.1 The function of diodes 9.6.2 The symbol for diodes 9.6.3 The position of diodes in a circuit Page 99 / 111
Delegates shall demonstrate: 9.6.4 How to check a diode with a multimeter ELEMENT 9.7 Bridge rectifiers Instructors shall explain and demonstrate: 9.7.1 The function of bridge rectifiers 9.7.2 The symbol for bridge rectifiers 9.7.3 The position of bridge rectifiers in a circuit Delegates shall demonstrate: 9.7.4 How to check a bridge rectifier with a multimeter ELEMENT 9.8 Capacitors Instructors shall explain and demonstrate: 9.8.1 The function of capacitors 9.8.2 The symbol for a capacitor 9.8.3 The position of capacitors in a circuit 9.8.4 The risks and hazards associated with stored energy Delegates shall demonstrate: 8.8.4 How to check a capacitor with a multimeter ELEMENT 9.9 Transformers 9.9.1 The function of transformers 9.9.2 The symbol for transformers 9.9.3 The position of transformers in a circuit Page 100 / 111
ELEMENT 9.10 Generators and motors 9.10.1 The basic function of generators and motors 9.10.2 The symbols of generators and motors 9.10.3 The position of generators and motors in a circuit ELEMENT 9.11 Fuses and circuit breakers 9.11.1 The function of fuses 9.11.2 The function of circuit breakers 9.11.3 The symbol for fuses 9.11.4 The symbol for circuit breakers 9.11.5 The position of fuses and circuit breakers in a circuit ELEMENT 9.12 Processor Control Systems 9.12.1 The function of Processor Control Systems 9.12.2 The position of the Processor Control System in the circuit Lesson 10 Sensors ELEMENT 10.1 Types 10.1.1 The general classification of the sensors used in the electrical systems Delegates shall engage in discussions of: 10.1.2 Different types, locations and functions of sensors Page 101 / 111
ELEMENT 10.2 Wind sensors 10.2.1 The function of wind sensors 10.2.2 The symbol for wind sensors 10.2.3 The different types of wind sensors 10.2.4 The position wind sensors in a circuit Delegates shall engage in discussions of: 10.2.5 The different types, locations and functions of sensors ELEMENT 10.3 Temperatures Instructors shall explain and demonstrate: 10.3.1 The function of temperature sensors (PT 100 and thermistor) 10.3.2 The symbol for temperature sensors (PT 100 and thermistor) 10.3.3 The position of temperature sensors in a circuit Delegates shall engage in discussions of: 10.3.4 The different types, locations and functions of sensors Delegates shall test: 10.3.5 How a PT 100 sensor functions when installed ELEMENT 10.4 Yaw sensors 10.4.1 The function of yaw sensors 10.4.2 The position of yaw sensors in a circuit Delegates shall engage in discussions of: 10.4.3 The locations and functions of yaw sensors Page 102 / 111
ELEMENT 10.5 Pressure sensors 10.5.1 The function of pressure sensors 10.5.2 The symbol for pressure sensors 10.5.3 The position of pressure sensors in a circuit Delegates shall engage in discussions of: 10.5.4 The locations and functions of the pressure sensors Lesson 11 Electrical circuits ELEMENT 11.1 Symbols and diagrams Instructors are to give: 11.1.1 An introduction to electrical diagrams Delegates shall explain: 11.1.2 Different components in a diagram Delegates shall demonstrate: 11.1.3 How to interpret electrical diagrams ELEMENT 11.2 Assembly of an electrical circuit Delegates shall demonstrate: 11.2.1 An assembly of an electrical circuit following a basic electrical diagram including the components mentioned in the equipment list in Section 2.6 as a minimum 11.2.2 The correct operation of the circuit Page 103 / 111
ELEMENT 11.3 Measuring points Instructors shall engage Delegates in discussions of: 11.3.1 The measuring points in a physical circuit 11.3.2 Identifying measuring points in a diagram Delegates shall practice and demonstrate: 11.3.3 How to check continuity in an electrical circuit 11.3.4 How to measure voltage AC and DC in an electrical circuit 11.3.5 How to measure current in an electrical circuit ELEMENT 11.4 The electrical WTG system 11.4.1 A single line diagram for the main power components in a WTG 11.4.2 An overview of the auxiliary circuit in a WTG 11.4.3 An overview of the communications and controllers in a WTG Lesson 12 Electric theory test ELEMENT 12.1 Test Instructors shall: 12.1.1 Conduct the test with the delegates Delegates shall: 12.1.2 Conduct the test within 30 minutes Instructors shall: 12.1.3 Check the test results and give feedback to the Delegates about the test result Page 104 / 111
Lesson 13 Evaluation ELEMENT 13.1 Summary Instructors shall: 13.1.1 Summarise the BMT Module and give the Delegates final feedback ELEMENT 13.2 Evaluation Delegates shall: 13.2.1 Conduct a written evaluation Instructors shall: 13.2.2 Give necessary feedback on the written evaluations Notes: The module 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 105 / 111
Section 2 Resources for BMT Electrical The Training Provider shall ensure that staff, 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 Electrical Module Practical 1:6 2.3 Facilities The full range of facilities shall be available during the training. The following facility criteria shall be adhered to. Page 106 / 111
2.4 Theoretical training facilities Facilities shall be designed to enable each Delegate to see, hear and fully appreciate 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 107 / 111
2.6 Equipment The following equipment is required during the entire duration of this BMT Electrical Training to meet the needs of the BMT Electrical Module. (1) PPE suitable for electrical work (2) LOTO equipment for electrical work (3) Multimeter (4) Amp Clamp Meter (5) Appropriate electrical wires (6) Different value resistances (7) Power source (8) Electrical circuit or board structures (9) Lamps (10) Switches (11) Capacitors (12) Diodes (13) DIN rail standard (14) Terminals for rail (15) Push buttons (NO and NC) (16) Contactors (17) Relays (18) Electrical protection (19) Emergency stop button (20) PT 100 sensor 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 108 / 111
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 Electric 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 Electric Module. 3.4 Control Measures Please find the Control Measures Form on next page. Page 109 / 111
Control Measure Name: Course: BMT Electrical 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 maintained 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 Page 110 / 111
Applies subject knowledge correctly in given scenario Demonstrates understanding of subject Total Marks 0 9 Pass 10 27 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 111 / 111