GLOBAL WIND ORGANISATION
STANDARD
Basic Maintenance Training (BMT)
(Onshore/Offshore)
Version 0
21 March, 2016
Global Wind Organisation
Standard
Basic Maintenance Training
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.
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Global Wind Organisation
Standard
Basic Maintenance Training
Version 0:
21 March, 2016
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
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
Duration of the BMT Hydraulics Module .......................................................................................................... 12
Target Group ....................................................................................................................................................... 12
Delegate prerequisites for the BMT Hydraulics Module ...................................................................................... 13
Physical demands of the BMT Hydraulics Module ............................................................................................ 13
Aims and objectives of the BMT Hydraulics Module ............................................................................................ 14
Learning outcomes of the BMT Hydraulics Module .......................................................................................... 16
Delegate Performance Assessment ...................................................................................................................... 23
BMT Hydraulics Module Time Table ................................................................................................................... 24
Elements, BMT Hydraulics Module ................................................................................................................. 26
SECTION 2 - RESOURCES FOR BMT HYDRAULICS ................................................................... 40
2.1
2.2
2.3
2.4
2.5
2.6
Instructors ........................................................................................................................................................... 40
Instructor/Delegate Ratio .................................................................................................................................... 40
Facilities ............................................................................................................................................................... 41
Theoretical Training Facilities .............................................................................................................................. 41
Practical Training Facilities .................................................................................................................................. 41
Equipment ........................................................................................................................................................... 42
SECTION 3 - ADMINISTRATION ............................................................................................. 43
3.1
3.2
3.3
3.4
Delegate performance assessment ...................................................................................................................... 43
Validity.................................................................................................................................................................. 43
Measures ............................................................................................................................................................. 43
Control Measures ................................................................................................................................................ 43
MODULE 2 – THE BMT MECHANICAL MODULE ..................................................................... 47
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Global Wind Organisation
Standard
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
Basic Maintenance Training
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21 March, 2016
Duration of the BMT Mechanical Module ............................................................................................................ 47
Target Group ....................................................................................................................................................... 47
Delegate prerequisites for the BMT Mechanical Module..................................................................................... 48
Physical demands of the BMT Mechanical Module .......................................................................................... 48
Aims and objectives of the BMT Mechanical Module .......................................................................................... 49
Learning outcomes of the BMT Mechanical Module ....................................................................................... 50
Delegate Performance Assessment ...................................................................................................................... 54
BMT Mechanical Module Time Table ................................................................................................................... 56
Elements, BMT Mechanical Module ................................................................................................................... 58
SECTION 2 – RESOURCES FOR BMT MECHANICAL ................................................................. 72
2.1
2.2
2.3
2.4
2.5
2.6
Instructors ........................................................................................................................................................... 72
Instructor/Delegate Ratio .................................................................................................................................... 72
Facilities ............................................................................................................................................................... 73
Theory training facilities ...................................................................................................................................... 73
Practical training facilities .................................................................................................................................... 73
Equipment ........................................................................................................................................................... 73
SECTION 3 - ADMINISTRATION ............................................................................................. 75
3.1
3.2
3.3
3.4
Delegate performance assessment ..................................................................................................................... 75
Validity ................................................................................................................................................................. 75
Measures ............................................................................................................................................................. 75
Control Measures ................................................................................................................................................ 75
MODULE 3 - THE BMT ELECTRICAL MODULE ......................................................................... 79
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
Duration of the BMT Electrical Module ................................................................................................................ 79
Target Group ....................................................................................................................................................... 80
Delegate prerequisites for the BMT Electrical Module ........................................................................................ 80
Physical demands of the BMT Electrical Module .................................................................................................. 80
Aims and objectives of the BMT Electrical Module .............................................................................................. 81
Learning outcomes of the BMT Electrical Module ............................................................................................... 82
Delegate Performance Assessment ...................................................................................................................... 88
BMT Electric Module Time Table .......................................................................................................................... 89
Elements, BMT Electric Module .......................................................................................................................... 91
SECTION 2 – RESOURCES FOR BMT ELECTRICAL .................................................................. 106
2.1
2.2
2.3
2.4
2.5
2.6
Instructors ......................................................................................................................................................... 106
Instructor/Delegate Ratio .................................................................................................................................. 106
Facilities ............................................................................................................................................................. 106
Theoretical training facilities ............................................................................................................................. 107
Practical Training Facilities ................................................................................................................................ 107
Equipment ......................................................................................................................................................... 108
SECTION 3 – ADMINISTRATION .......................................................................................... 109
3.1
3.2
3.3
3.4
Delegate performance assessment ................................................................................................................... 109
Validity ............................................................................................................................................................... 109
Measures ........................................................................................................................................................... 109
Control Measures .............................................................................................................................................. 109
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Global Wind Organisation
Standard
Basic Maintenance Training
Version 0:
21 March, 2016
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.
List of Abbreviations
GWO
BMT
WTG
PPE
LOTO
Global Wind Organisation
Basic Maintenance Training
Wind Turbine Generator
Personal Protective Equipment
Lock Out Tag Out
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Global Wind Organisation
Standard
Basic Maintenance Training
Version 0:
21 March, 2016
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
Duration of BMT Modules
Modules
Hydraulics
Mechanical
Electrical
Duration
16 hours
16 hours
20 hours
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Global Wind Organisation
Standard
Basic Maintenance Training
Version 0:
21 March, 2016
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.
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Global Wind Organisation
Standard
Basic Maintenance Training
Version 0:
21 March, 2016
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.
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Global Wind Organisation
Standard
Basic Maintenance Training
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21 March, 2016
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.
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Global Wind Organisation
Standard
Basic Maintenance Training
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21 March, 2016
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.
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Global Wind Organisation
Standard
Basic Maintenance Training
Version 0:
21 March, 2016
GLOBAL WIND ORGANISATION
STANDARD
Basic Maintenance Training (BMT)
(Onshore/Offshore)
HYDRAULICS MODULE
Version 0
21 March, 2016
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Global Wind Organisation
Standard
Basic Maintenance Training
Version 0:
21 March, 2016
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.
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Global Wind Organisation
Standard
1.3
Basic Maintenance Training
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21 March, 2016
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.
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Global Wind Organisation
Standard
1.5
Basic Maintenance Training
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21 March, 2016
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
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Global Wind Organisation
Standard
Basic Maintenance Training
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21 March, 2016
(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
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Global Wind Organisation
Standard
1.6
Basic Maintenance Training
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21 March, 2016
Learning outcomes of the BMT
Hydraulics Module
The learning outcomes specified for the Hydraulics Module are:
Lesson 1
Introduction
30 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)
(2)
(3)
(4)
(5)
(6)
Safety instructions and emergency procedures
Facilities
Who the instructor and other Delegates are
The aims and main learning objectives
On-going assessment according to GWO Control Measures
Motivation on the course
Note: The administrative part of the registration should be carried out before the course
commences.
Lesson 2
Hydraulics Introduction
30 min.
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
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Global Wind Organisation
Standard
Lesson 3
Basic Maintenance Training
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21 March, 2016
Risks and hazards
45 min.
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)
(2)
(3)
(4)
Explain the risks and hazards of high pressure in hydraulic systems
Explain the risks and hazards of oil in hydraulic systems
Explain the safety conditions required to work with the accumulator
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
Prevention of un-expected start up
60 min.
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
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Global Wind Organisation
Standard
Lesson 6
Basic Maintenance Training
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21 March, 2016
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
Actuator
30 min.
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
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Standard
Lesson 9
Basic Maintenance Training
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21 March, 2016
Proportional valves
30 min.
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)
(2)
(3)
(4)
(5)
(6)
(7)
Explain the different pressure and flow valves in a circuit
Demonstrate how to check and adjust the pressure relief valve
Explain the principle of the operation of a pressure reduction valve
Demonstrate how to operate a needle valve
Explain the principle of the operation of a non-return valve
Explain the principle of the operation of a Throttle valve
Explain the principle of the operation of an orifice/restrictor valve
Lesson 11
Accumulators
90 min.
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)
(2)
(3)
(4)
Explain the function of the accumulators in the circuit
Explain the different types of accumulator and their different parts
Explain the handling and storage of the nitrogen bottles
Demonstrate how to check the pre-charge pressure and refill the accumulator
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Global Wind Organisation
Standard
Lesson 12
Basic Maintenance Training
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21 March, 2016
Sensors
30 min.
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
Pipes, hoses and connections
30 min.
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
Oil and filters
60 min.
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)
(2)
(3)
(4)
(5)
(6)
Describe different types of oils
Describe the handling of oil procedures and cleanliness
Describe the importance of an oil sample
Demonstrate how to check oil level
Describe different types of filters and their function
Describe the filter conditions and their maintenance
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Global Wind Organisation
Standard
Lesson 15
Basic Maintenance Training
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21 March, 2016
Pressure gauges/manometers
30 min.
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
Hydraulic Theory Test
60 min.
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.
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Lesson 18
Basic Maintenance Training
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21 March, 2016
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
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Global Wind Organisation
Standard
1.7
Basic Maintenance Training
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21 March, 2016
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.
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Global Wind Organisation
Standard
1.8
Basic Maintenance Training
Version 0:
21 March, 2016
BMT Hydraulics Module Time Table
The order in which the elements of the Training Module are delivered may vary.
Approximate
Lesson
Element
Duration
1
Introduction
1.1 Safety instructions and
emergency procedures
1.2 Facilities
1.3 Introduction
1.4 Scope and main objectives
1.5 On-going assessments
1.6 Motivation
TOTAL
30 min.
2
Hydraulics introduction
2.1 The hydraulic system
2.2 Pascal’s law
2.3 Transmission ratio
TOTAL
30 min.
3
Risks and hazards
3.1 High pressure systems
3.2 Oil
TOTAL
45 min.
4
Hydraulic PPE
4.1 Types of PPE
4.2 Proper inspections
4.3 Correct uses
TOTAL
30 min.
5
Prevention of un5.1 Importance of Lock Out Tag Out
expected start-up
TOTAL
60 min.
6
Pumps
6.1 Gear pumps
6.2 Piston pumps
6.3 Pumps exercise
TOTAL
60 min.
7
Actuator
7.1 Types
7.2 Hydraulic cylinders
TOTAL
30 min.
8
Directional control valves 8.1 Types
9
Proportional valves
9.1
TOTAL
Principle of operation
TOTAL
45 min.
30 min.
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Global Wind Organisation
Standard
10
Basic Maintenance Training
Pressure and flow valves
11
Accumulators
12
Sensors
Pressure relief valves
Pressure reduction valves
Needle valves
Non return valves
Throttle valves
Orifice/restrictor valves
TOTAL
11.1 Use and types
11.2 Safety
11.3 Pre-charge pressure
10.1
10.2
10.3
10.4
10.5
10.6
TOTAL
12.1 Pressure sensors
12.2 Temperature sensors
12.3 Flow sensors
TOTAL
13
Pipes, hoses and
connections
15
Oil and filters
Pressure
gauges/manometers
90 min.
90 min.
30 min.
13.1 Oil Transfer
13.2 Hydraulic connections
TOTAL
14
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21 March, 2016
30 min.
14.1 Oil
14.2 Handling oil
procedures/cleanliness
14.3 Collecting an oil sample
14.4 Check oil level
14.5 Filters
15.1
15.2
15.3
TOTAL
Pressure gauge/manometer
characteristics
Check calibration
Pressure measuring
TOTAL
Main symbols and components
Identifying measuring points
16
Symbols and Diagrams
16.1
16.2
17
Hydraulic Theory Test
17.1 Test
60 min.
30 min.
60 min.
18
Evaluation
TOTAL
60 min.
TOTAL
30 min.
840 min.
18.1 Summary
18.2 Evaluation
18.3 Certificates
GRAND TOTAL
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Global Wind Organisation
Standard
1.9
Basic Maintenance Training
Version 0:
21 March, 2016
Elements, BMT Hydraulics
Module
Lesson 1
Introduction
ELEMENT 1.1 Safety instructions and emergency procedures
Instructors shall explain:
1.1.1
1.1.2
Safety instructions according to internal procedures
Emergency procedures and emergency exits in the localities the
Delegates can be expected to be located during the course
ELEMENT 1.2 Facilities
Instructors shall explain:
1.2.1
General description of the facilities on the location
(Administration, dining area, restrooms and 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
Instructors shall explain:
1.3.3
The programme of the BMT Module, including breaks and meal times
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ELEMENT 1.4 Scope and main objectives
Instructors shall explain:
1.4.1
Scope and main objectives of this BMT Module
ELEMENT 1.5 On-going assessments
Instructors shall explain:
1.5.1
1.5.2
The reasons for the on-going assessment
GWO Control Measures and their use
ELEMENT 1.6 Motivation
Instructors shall explain:
1.6.1
Lesson 2
The importance of personal involvement in the course
Hydraulics introduction
ELEMENT 2.1 The hydraulic system
Instructors shall explain:
2.1.1
2.1.2
Introduction to pressure
The typical components in a hydraulic system (e.g. pump, tank, hoses,
valves)
ELEMENT 2.2 Pascal’s law
Instructors shall explain:
2.2.1
2.2.2
The basic concept regarding the incompressibility of fluid and how force
can be transferred from one cylinder to another
Practical examples of Pascal’s law
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ELEMENT 2.3 Transmission ratio
Instructors shall lead discussion of:
2.3.1
Lesson 3
How it is possible to increase and decrease the force by using the same
pressure
Risks and hazards
ELEMENT 3.1 High pressure systems
Instructors shall explain and lead discussion of:
3.1.1
3.1.2
The hazards caused by exposure to high pressure oil (e.g. cuts, oil
injections) and nitrogen (e.g. nitrogen in the lungs, high pressure, stored
energy, cold burns, squeeze and punch)
The importance of checking and relieving system pressure including
accumulators (e.g. test points, manometers and needle valves)
ELEMENT 3.2 Oil
Instructors shall explain and lead discussion of:
3.2.1
3.2.2
Lesson 4
The hazards caused by being exposed to hydraulic oil
The need of Material Safety Data Sheets (MSDS)
Hydraulic PPE
ELEMENT 4.1 Types of PPE
Instructors shall explain and demonstrate:
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
A glove suitable for hydraulic work
That not all gloves are suitable for hydraulic work
The consequence of not wearing the right PPE
Which goggles can be used for hydraulic work
The importance of wearing goggles when working with hydraulic systems
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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
4.3.2
Lesson 5
How to choose the right PPE to wear for hydraulic work
How to inspect and use hydraulic PPE
Prevention of un-expected start-up
ELEMENT 5.1 Importance of Lock Out Tag Out
Instructors shall explain and demonstrate:
5.1.1
5.1.2
The importance of Lock Out Tag Out
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
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Global Wind Organisation
Standard
Lesson 6
Basic Maintenance Training
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21 March, 2016
Pumps
ELEMENT 6.1 Gear pumps
Instructors shall explain and demonstrate:
6.1.1
6.1.2
6.1.3
The parts of a gear pump
How a gear pump works
The symbol used in the diagram
ELEMENT 6.2 Piston pumps
Instructors shall explain and demonstrate:
6.2.1
6.2.2
6.2.3
The parts of a piston pump
How a piston pump works
The symbol used in the diagram
ELEMENT 6.3 Pumps exercise
Instructors shall explain and demonstrate:
6.3.1
The process to check the start and stop pressure on a pump
Delegates are to practice and demonstrate:
6.3.2
Lesson 7
How to check the start and stop pressure on a pump following the
instructions from the trainer
Actuators
ELEMENT 7.1 Types
Instructors shall explain:
7.1.1
7.1.2
7.1.3
The different types of actuators (e.g. cylinders and callipers)
The use of each type of actuator
The symbol for an actuator
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ELEMENT 7.2 Hydraulic cylinders
Instructors shall explain:
7.2.1
7.2.2
Lesson 8
Examples of faulty cylinders (e.g. pistons)
The hazards which may occur (e.g. causes of leaks and pressure drop)
Directional control valves
ELEMENT 8.1 Types
Instructors shall explain:
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.1.6
The different types of directional valves (e.g. 2/3, 3/4)
The principle of operation of directional valves
That the directional control valve has been named based on how many
ports and positions it has
That valves are shown de-energised in the diagram
The difference between an electrical operated valve and a pilot operated
valve
The symbol for an electrical operated valve and pilot operated valve
Delegates are to engage in discussions of:
8.1.7
Lesson 9
The operation of directional valves
Proportional valves
ELEMENT 9.1 Principle of operation
Instructors shall explain:
9.1.1
9.1.2
9.1.3
The use of proportional valves in a hydraulic circuit
The principle of operation of the proportional valves
The symbol for a proportional valve
Delegates are to engage in discussions of:
9.1.4
The operation of a proportional valve in a circuit
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Global Wind Organisation
Standard
Lesson 10
Basic Maintenance Training
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21 March, 2016
Pressure and flow valves
ELEMENT 10.1 Pressure relief valves
Instructors shall explain and demonstrate:
10.1.1
10.1.2
10.1.3
10.1.4
The function of the pressure relief valve and how it works
The position of a pressure relief valve in a circuit
How to check and adjust the pressure relief valve
The symbol for a pressure relief valve
Delegates are to practice and demonstrate:
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
10.2.2
10.2.3
The function of the pressure reduction valve and how it works
The position of a pressure reduction valve in a circuit
The symbol for a pressure reduction valve
ELEMENT 10.3 Needle valves
Instructors shall explain and demonstrate:
10.3.1
10.3.2
10.3.3
The function of the needle valve in a circuit
The position of a needle valve in a circuit
The symbol for a needle valve
Delegates are to practice and demonstrate:
10.3.4
10.3.5
The operation of the needle valve in a circuit
The use of a needle valve to depressurize the hydraulic system
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ELEMENT 10.4 Non return valves
Instructors shall explain:
10.4.1
10.4.2
10.4.3
10.4.4
10.4.5
The function of a non-return valve
The function of a pilot operated non-return valve
The position of a non-return valve in a circuit
The symbol for a non-return valve
The symbol for a pilot operated non-return valve
ELEMENT 10.5 Throttle valves
Instructors shall explain:
10.5.1
10.5.2
10.5.3
The function of a throttle valve
The position of a throttle valve in a circuit
The symbol for a throttle valve
ELEMENT 10.6 Orifice/restrictor valves
Instructors shall explain:
10.6.1
10.6.2
10.6.3
Lesson 11
The function of an orifice/restrictor valve
The position of an orifice/restrictor valve in a circuit
The symbol for an orifice/restrictor valve
Accumulator
ELEMENT 11.1 Use and types
Instructors shall explain and demonstrate:
11.1.1
11.1.2
11.1.3
The different types of accumulators (bladder, piston and diaphragm)
The function of the accumulators in a circuit
The symbol for an accumulator
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ELEMENT 11.2 Safety
Instructors shall explain and demonstrate:
11.2.1
11.2.2
11.2.3
11.2.4
Principal characteristics of Nitrogen
Nitrogen bottles storage and handling requirements
The importance of discharging the accumulators prior to working on the
system
The risks associated with a charged accumulator
ELEMENT 11.3 Pre-charge pressure
Instructors shall explain and demonstrate:
11.3.1
11.3.2
How to check the pre-charge pressure of an accumulator
The temperature correction chart
Delegates shall practice and demonstrate:
11.3.3
11.3.4
Lesson 12
How to check the pre-charge pressure of an accumulator
How to refill the accumulator
Sensors
ELEMENT 12.1 Pressure sensors
Instructors shall explain:
12.1.1
12.1.2
12.1.3
The function of the pressure transducer and pressure switch
The position of the pressure transducer and pressure switch in a circuit
The symbol for a pressure transducer and pressure switch
ELEMENT 12.2 Temperature sensors
Instructors shall explain:
12.2.1
12.2.2
12.2.3
The function of the temperature sensor
The position of the temperature sensor in a circuit
The symbol for a temperature sensor
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ELEMENT 12.3 Flow sensors
Instructors shall explain:
12.3.1
12.3.2
12.3.3
The function of the flow sensor
The position of the flow sensor in a circuit
The symbol for a flow sensor
Delegates shall engage in discussions of:
12.3.4
Lesson 13
Different types, location and functions of sensors
Pipes, hoses and connections
ELEMENT 13.1 Oil Transfer
Instructors shall describe:
13.1.1
13.1.2
13.1.3
13.1.4
13.1.5
The function of hydraulic pipes and hoses
The position of the pipes and hoses in a circuit
The different types of pipes, hoses and fittings used in hydraulic systems
The symbol for a hose
The risks and hazards associated with pipes and hoses
ELEMENT 13.2 Hydraulic connections
Instructors shall describe:
13.2.1
13.2.2
13.2.3
Lesson 14
How to make a connection with different fittings
The function of quick release couplings
The symbol for a quick release coupling
Oil and filters
ELEMENT 14.1 Oil
Instructors shall describe:
14.1.1
The characteristics of different types of oil
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ELEMENT 14.2 Handling oil procedures/cleanliness
Instructors shall describe:
14.2.1
14.2.2
14.2.3
The personal safety involved when handling oil
The environmental safety involved when handling oil
The importance of cleanliness
ELEMENT 14.3 Collecting an oil sample
Instructors shall describe:
14.3.1
The importance of collecting an oil sample
ELEMENT 14.4 Checking oil level
Instructors shall explain and demonstrate:
14.4.1
14.4.2
14.4.3
14.4.4
The function of the tank
Oil level checking with a dip stick
Oil level checking with a sight glass
Oil level checking with a filling hole
Delegates shall practice and demonstrate:
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
14.5.2
14.5.3
14.5.4
14.5.5
14.5.6
The function of the filters
The different types of filters
The particle sizes
The importance of replacing filters
The symbol for filters
The position of filters in a circuit
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Global Wind Organisation
Standard
Lesson 15
Basic Maintenance Training
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21 March, 2016
Pressure gauges/manometers
ELEMENT 15.1 Pressure gauge/manometer characteristics
Instructors shall explain and demonstrate:
15.1.1
15.1.2
The characteristic of pressure gauges/manometers
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
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Global Wind Organisation
Standard
Lesson 16
Basic Maintenance Training
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21 March, 2016
Symbols and diagrams
ELEMENT 16.1 Main symbols and components
Instructors shall summarise:
16.1.1
16.1.2
The symbols that represent each components of a hydraulic circuit
The symbols of the main elements in a diagram
ELEMENT 16.2 Identifying measuring points
Instructors shall explain:
16.2.1
16.2.2
The accurate measuring points in a circuit
The symbol of measuring points
Delegates shall engage in discussions of:
16.2.3
16.2.4
Lesson 17
Hydraulic systems and the symbols used in hydraulic circuit diagrams
Identifying accurate measuring points using a diagram
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
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Global Wind Organisation
Standard
Lesson 18
Basic Maintenance Training
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21 March, 2016
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.
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Standard
Basic Maintenance Training
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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
BMT Hydraulics Module
Session
Theory
Practical
Instructor – Delegate Ratio
1:12
1:6
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Standard
2.3
Basic Maintenance Training
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21 March, 2016
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.
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Global Wind Organisation
Standard
2.6
Basic Maintenance Training
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21 March, 2016
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)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
PPE suitable for hydraulic work
LOTO equipment
Tank
Pump with electrical motor
Directional valve
Needle valve
Pressure relief valve
Non-return valve
Pressure switch
Actuator
Accumulator
Test points
Oil
Filters
Pressure gauge/manometer
Filling kit for nitrogen
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
UK – BS
USA – ANSI
Canada – CSA
Australia and New Zealand – AS/NZS
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.
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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.
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Global Wind Organisation
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Basic Maintenance Training
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Name: __________________________________
Course: BMT Hydraulics Module
Date: ________
Scenario Organisation
Training Provider: __________________
Violation of
Assessment
Measures
0-2
Passed/
3 Failed
Instructor Remarks
Aware of personal and
group safety at all times
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
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Demonstrates
understanding of subject
Total Marks
0–9
10 – 27
Pass
Fail
Instructor: _____________________________________________________________
□ PASS
□ FAIL
The practical Assessment Measures Form is a final evaluation tool for the instructors to assess
Delegates during practical elements. It allows measurement of the number of violations in
regard to safety, competency, or attitude. It can be used as a progressive evaluation tool to
discuss the performance of a Delegate in guiding them to success and it also serves as
supporting documentation when a Delegate fails the Module.
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Basic Maintenance Training
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GLOBAL WIND ORGANISATION
STANDARD
Basic Maintenance Training (BMT)
(Onshore/Offshore)
MECHANICAL MODULE
Version 0
21 March, 2016
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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.
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1.3
Basic Maintenance Training
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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.
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1.5
Basic Maintenance Training
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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.
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1.6
Basic Maintenance Training
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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)
(2)
(3)
(4)
(5)
(6)
Safety instructions and emergency procedures
Facilities
Who the instructor and other Delegates are
The aims and main learning objectives
On-going assessment according to GWO Control Measures
Motivation on the course
Note: The administrative part of the registration should be carried out before the course
commences.
Lesson 2
Mechanical Introduction
90 min.
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
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Lesson 3
Basic Maintenance Training
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21 March, 2016
The principles of bolted and welded
connections
165 min.
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
Use of tools and measuring equipment
for wind turbine maintenance
120 min.
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)
(2)
(3)
(4)
(5)
(6)
(7)
Demonstrate how to select and use the correct spanners for bolted connections
Demonstrate how to select and use the correct screw drivers for screwed connections
Demonstrate how to adjust and use a torque wrench
Demonstrate how to measure gaps between components using feeler gauges
Demonstrate how to take measurements using a calliper
Demonstrate how to check the run out of a disc using a dial gauge
Explain what a laser alignment tool is used for
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Lesson 5
Basic Maintenance Training
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21 March, 2016
Gearbox
45 min.
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
Braking system and coupling
90 min.
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)
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Lesson 7
Basic Maintenance Training
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21 March, 2016
Yaw system
60 min.
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
Cooling- and lubrication system
180 min.
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
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Lesson 9
Basic Maintenance Training
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21 March, 2016
Mechanical Theory Test
60 min.
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).
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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.
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Standard
1.8
Basic Maintenance Training
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21 March, 2016
BMT Mechanical Module Time Table
The order in which the elements of the Training Module are delivered may vary.
Lesson
1
Introduction
Element
1.1
1.2
1.3
1.4
1.5
1.6
2
Mechanical
introduction
2.1
2.2
2.3
2.4
3
The principles of
bolted and welded
connections
3.1
3.2
3.3
3.4
3.5
4
Use of tools and
measuring equipment
for wind turbine
maintenance
4.1
4.2
4.3
4.4
4.5
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
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
Approximate
Duration
15 min.
90 min.
165 min.
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Basic Maintenance Training
4.6
4.7
5
Gearbox
5.1
5.2
5.3
6
Braking system and
coupling
6.1
6.2
6.3
6.4
7
Yaw System
7.1
7.2
7.3
8
Cooling and
Lubrication System
8.1
8.2
8.3
8.4
8.5
8.6
8.7
9
Mechanical Theory
Test
9.1
Checking the run out of a disc
and using a dial indicator
Introduction to the laser
alignment tool
TOTAL
The function and operating
principles
Hazards and risks associated
with the gearbox and coupling
Inspections
TOTAL
The function of the disc and
the aerodynamic brake
The function of the coupling
Hazards and risks associated
with the brake system
Inspection of the braking
system
TOTAL
The function of the Yaw
system
The components of the Yaw
system and their functions
Hazards and risks associated
with the Yaw system
TOTAL
Components requiring cooling
and why
Interconnection of individual
components
Components of the lubrication
and maintenance of levels
The effects of malfunctions on
the operation of the turbine
systems
Hazards and risks associated
with the lubrication and
cooling systems
Inspection of the lubrication
and cooling systems
Recognizing damage and
completing the documentation
TOTAL
Test
TOTAL
Version 0:
21 March, 2016
120 min.
45 min.
90 min.
60 min.
180 min.
60 min.
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Global Wind Organisation
Standard
10 Evaluation
Basic Maintenance Training
10.1
10.2
10.3
Version 0:
21 March, 2016
Summary
Evaluation
Certificates
TOTAL
GRAND TOTAL
1.9
15 min.
840 min.
Elements, BMT Mechanical Module
Lesson 1
Introduction
ELEMENT 1.1 Safety instructions and emergency procedures
Instructors shall explain:
1.1.1
1.1.2
Safety instructions according to internal procedures
Emergency procedures and emergency exits in the localities the
Delegates can be expected to be located during the course
ELEMENT 1.2 Facilities
Instructors shall explain:
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
Instructors shall explain:
1.3.3
The programme of the BMT Module, including breaks and meal times
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ELEMENT 1.4 Scope and main objectives
Instructors shall explain:
1.4.1
Scope and main objectives of this BMT Module
ELEMENT 1.5 On-going assessments
Instructors shall explain:
1.5.1
1.5.2
The reasons for the on-going assessment
GWO Control Measures and their use
ELEMENT 1.6 Motivation
Instructors shall explain:
1.6.1
Lesson 2
The importance of personal involvement in the course
Mechanical Introduction
ELEMENT 2.1 Main components of the structure
Instructors shall explain:
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
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ELEMENT 2.2 Main mechanical systems
Instructors shall explain:
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
Instructors shall explain:
2.3.1
2.3.2
2.3.3
2.3.4
Energy changing from linear to rotational motion and to electrical
energy
Wind speed/velocity and direction
The basic aerodynamics of the blade
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
Instructors shall explain:
2.4.1
2.4.2
2.4.3
2.4.4
The safety risks and hazards in mechanical systems (e.g. bruises,
squeezing, rotation, fluids, trapping, slipping, pinching)
The importance of working according to approved working practices
The PPE requirements for working on mechanical systems
The need for Material Safety Data Sheets (MSDS)
Delegates shall engage in discussions of:
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2.4.5
Lesson 3
Basic Maintenance Training
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Safe working procedures, identifying the necessary PPE and appropriate
tools
The principles of bolted and welded
connections
ELEMENT 3.1 The principles of threaded components
Instructors shall explain:
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.1.7
3.1.8
3.1.9
3.1.10
3.1.11
3.1.12
3.1.13
The meaning of pitch of a thread
The angle of a thread
The outside and core diameters of threads
Right and left hand threads
Strength proportional to size of the bolt
Strength due to material
Function and types of washers
Force x length with reference to spanners.
Importance of correct torque (e.g. collapsing towers, electrical fires)
Lubrication
That bolts and nuts need the same temperature
The difference between torque and tension
The principles of angular tightening
Delegates shall engage in discussions of:
3.1.14
3.1.15
Bolts, threads, strengths of materials and temperature influences
Force and torque
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ELEMENT 3.2
Basic Maintenance Training
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The locations of important bolted and welded
connections
Instructors shall explain:
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.6
3.2.7
3.2.8
Connection between tower and transition piece
Connections between sections of the tower
Platforms in the tower
Ladders in the tower
Guard rails on the transition piece
An example of a bolted connection and a welded connection
Bolted connections holding cranes
Bolted connections with the Fall Arrester system
Bolted connections on the rotor, coupling, gearbox and generator
Delegates shall engage in discussions of:
3.2.9
ELEMENT 3.3
Importance of maintenance and maintenance processes for bolted
connections
The inspection of welded joints
Instructors shall explain:
3.3.1
3.3.2
3.3.3
3.3.4
What a good weld is and how to recognise it
What a damaged weld is and how to recognise it
How to clean a suspect weld using sand paper and use a dye
penetrant spray to check it
The importance of using documentation in the event of identifying a
damaged welded joint
ELEMENT 3.4 Checking bolt connections and correct
tightening tools
Instructors shall explain:
3.4.1
3.4.2
How to check if a bolt is loose
What the correct tool is for tightening bolts
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ELEMENT 3.5 Recognise damage by visual inspection
Instructors shall explain:
3.5.1
3.5.2
3.5.3
3.5.4
How to recognise paint damage
How to recognise corrosion
How to recognise cracks
How to recognise leaks
Delegates shall engage in discussions of:
3.5.5
Lesson 4
ELEMENT 4.1
Recognition of damage, corrosion and leaks of bolted or welded
connections and the consequences of not repairing them
Use of tools and measuring equipment for
wind turbine maintenance
Selecting and using the correct spanners for
bolted connections
Instructors shall explain and demonstrate:
4.1.1
4.1.2
4.1.3
4.1.4
Types of spanners
Correct application of spanner types
Use of correct size of spanner
Consequences of incorrect spanner use
Delegates shall practice and demonstrate:
4.1.5
Selecting and using spanners
ELEMENT 4.2 Selecting and using the correct screw drivers for
screwed connections
Instructors shall explain and demonstrate:
4.2.1
4.2.2
4.2.3
Types of screw drivers
Correct application of screw driver type
Consequences of incorrect use
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Delegates shall practice and demonstrate:
4.2.4
Selecting and using screw drivers
ELEMENT 4.3 Correctly setting and using a torque wrench
Instructors shall explain and demonstrate:
4.3.1
4.3.2
How to use the torque wrench
The importance of checking calibration
Delegates shall practice and demonstrate:
4.3.3
Setting and using torque wrenches
ELEMENT 4.4 Accurately gauging gaps between components
Instructors shall explain and demonstrate:
4.4.1
4.4.2
How to use feeler gauges
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
4.5.2
How to care for callipers
How to take measurements using callipers
Delegates shall practice and demonstrate:
4.5.3
Measuring thicknesses, internal diameters and depth using a calliper
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ELEMENT 4.6 Checking the run out of a disc and using a dial
indicator
Instructors shall explain and demonstrate:
4.6.1
4.6.2
How to use a dial indicator
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
Instructors shall explain:
4.7.1
Lesson 5
What a laser alignment tool can be used for
Gearbox
ELEMENT 5.1 The function and operating principles
Instructors shall explain:
5.1.1
5.1.2
The main function of the gearbox
The operation of the gearbox
ELEMENT 5.2 Risks and hazards associated with the gearbox
and coupling
Instructors shall explain:
5.2.2
5.2.2
5.2.3
The importance of locking the system so that it cannot turn (LOTO)
The hazards associated with gearbox oil
The correct PPE
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ELEMENT 5.3
Basic Maintenance Training
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Inspections
Instructors shall explain:
5.3.1
5.3.2
5.3.3
5.3.4
Lesson 6
Checking hoses, what to look for
Checking seals, what to look for
The importance of the right oil level
The importance of taking oil sample
Braking system and coupling
ELEMENT 6.1 The function of the disc and the aerodynamic
brake
Instructors shall explain:
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
The purpose of the disc brake
The purpose of the aerodynamic brake
The consequences of it not functioning
The operating principle of the disc brake
The operating principle of the aerodynamic brake
ELEMENT 6.2 The function of the coupling
Instructors shall explain:
6.2.1
The function of the coupling
ELEMENT 6.3 Risks and hazards associated with the brake
system
Instructors shall explain:
6.3.1
6.3.2
The necessity for LOTO (e.g. risk of moving parts, pressurized systems)
The correct PPE associated with the brake system
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ELEMENT 6.4 Inspection of the braking system
Instructors shall explain:
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
6.4.4
Lesson 7
Checking the thickness of the brake pads.
Measuring thickness of disc
Yaw system
ELEMENT 7.1 The function of the Yaw system
Instructors shall explain:
7.1.1
The function of the yaw system
ELEMENT 7.2 The components of the yaw system and their
functions
Instructors shall explain:
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
The yaw gear and its function
The yaw gear motors and their function
The wind sensor and its function
The anti-twist protection mechanism
The lubrication system
The yaw ball bearing and sliding bearing system
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ELEMENT 7.3 Risks and hazards associated with the yaw
system
Instructors shall explain:
7.3.1
The importance of LOTO
Delegates shall engage in discussions of:
7.3.2
Lesson 8
The dangers connected with the yaw system and how to minimise
them
Cooling and lubrication system
ELEMENT 8.1 Components that require cooling and why
Instructors shall explain:
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
How heat is produced by turning the gearbox
How heat is produced in the generator
How heat is produced by pressurising the hydraulic system
How overheating can make the machines become inefficient
How failure to control the temperature can result in failure of the
system
ELEMENT 8.2 Interconnection of individual components
Instructors shall explain:
8.2.1
8.2.2
8.2.3
That all the components of the turbine are reliant on each other
That heat can be transferred from component to component
That expansion due to heat can cause failure of the system
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ELEMENT 8.3 Components of the lubrication and the
maintenance of levels
Instructors shall explain:
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.3.6
8.3.7
How oil and grease reduces friction and lowers the production of heat
How oil is pumped around the gearbox to keep the temperature
down
The use of heat exchangers and radiators to reduce the heat in a
system
That some systems have a cooling system that employs a cooling
liquid in a discrete circuit
That oil and grease pumps can be used to keep the bearings, yaw and
pitch systems lubricated to reduce friction and corrosion
The importance of maintaining the correct levels in the systems
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
Instructors shall explain:
8.4.1
8.4.2
8.4.3
8.4.4
The consequences of a gearbox failure
The consequences of a pitch system failure
The consequences of a yaw system failure
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
8.5.2
8.5.3
8.5.4
Hazards of pressurised systems
Hazards of hot components
Hazards of oils and greases
The use of PPE
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8.5.5
Basic Maintenance Training
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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
Instructors shall explain:
8.6.1
8.6.2
8.6.3
8.6.4
8.6.5
How to visually check hoses for damage (e.g. pin holes, cracks, cuts,
friction marks, leaks)
How to visually check fittings for leaks
The importance of checking the cooling liquid
The importance of oil inspection (e.g. level, oil sample)
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
8.6.8
Correct use of PPE and working procedures for inspecting cooling and
lubrication systems
Visual inspection of cooling and/or lubricating systems
ELEMENT 8.7 Recognising damage and completing
documentation
Instructors shall explain:
8.7.1
8.7.2
8.7.3
8.7.4
What damage to look for on hoses
What damage to look for on fittings, washers and seals
What damage to look for on heat exchangers
The importance of documenting any damage found
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Lesson 9
Basic Maintenance Training
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21 March, 2016
Mechanical theory test
ELEMENT 9.1 Test
Instructors shall:
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
Lesson 10
Check the test results and give feedback to the Delegates about the test
result
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.
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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
BMT Mechanical Module
Session
Theory
Practical
Instructor – Delegate Ratio
1:12
1:6
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2.3
Basic Maintenance Training
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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)
(2)
(3)
(4)
(5)
PPE suitable for mechanical work
Spanners
Screwdrivers
Torque wrenches
Hexagon (Allen) keys
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(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
UK – BS
USA – ANSI
Canada – CSA
Australia and New Zealand – AS/NZS
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.
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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.
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Control Measure
Name: __________________________________
Course: BMT Mechanical Module
Date: ________
Scenario Organisation
Training Provider: __________________
Violation of
Assessment
Measures
0-2
Passed/
3 Failed
Instructor Remarks
Aware of personal and
group safety at all times
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
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Applies subject
knowledge correctly in
given scenario
Demonstrates
understanding of subject
Total Marks
0–9
10 – 27
Pass
Fail
Instructor: _____________________________________________________________
□ PASS
□ FAIL
The practical Assessment Measures Form is a final evaluation tool for the instructors to assess
Delegates during practical elements. It allows measurement of the number of violations in
regard to safety, competency, or attitude. It can be used as a progressive evaluation tool to
discuss the performance of a Delegate in guiding them to success and it also serves as
supporting documentation when a Delegate fails the Module.
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Basic Maintenance Training
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GLOBAL WIND ORGANISATION
STANDARD
Basic Maintenance Training (BMT)
(Onshore/Offshore)
ELECTRICAL MODULE
Version 0
21 March, 2016
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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.
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1.2
Basic Maintenance Training
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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.
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1.5
Basic Maintenance Training
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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.
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Standard
1.6
Basic Maintenance Training
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21 March, 2016
Learning outcomes of the BMT
Electrical Module
The learning outcomes specified for the Basic Electric Module are:
Lesson 1
Introduction
30 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)
(2)
(3)
(4)
(5)
(6)
Safety Instructions and Emergency Procedures
Facilities
Who the instructor and other Delegates are
The aims and main learning objectives
On-going assessment according to GWO Control Measures
Motivation on the course
Note: The administrative part of the registration should be carried out before the course
commences.
Lesson 2
Introduction to electricity
90 min.
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
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Lesson 3
Basic Maintenance Training
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21 March, 2016
Alternating current introduction
60 min.
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
Electrical measuring instruments
90 min.
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
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Lesson 5
Basic Maintenance Training
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Electrical hazards
120 min.
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)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Explain the effect on the body of an electrical contact
Explain direct and indirect contact situations
Explain hazards related to cables in a wind turbine
Explain hazards related to high voltage
Explain the electrical hazards related to the busbars
Explain protective earth
Explain the risks associated with stored energy
Explain static electricity as a hazard
Lesson 6
Safety signs
15 min.
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
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Lesson 7
Basic Maintenance Training
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Personal protective equipment and tools
45 min.
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
Prevention of unexpected start-up
45 min.
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
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Lesson 9
Basic Maintenance Training
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Components and symbols
165 min.
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
Sensors
225 min.
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)
(2)
(3)
(4)
(5)
Explain the different types of sensors and their symbols
Explain the function of the wind sensors
Explain the function of a temperature sensor and test it
Explain the function of a yaw sensor
Explain the function of a pressure sensor
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Lesson 11
Basic Maintenance Training
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21 March, 2016
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)
(2)
(3)
(4)
Explain components of an electric circuit in a diagram
Demonstrate how to interpret basic electrical diagrams
Demonstrate how to assemble a simple electric circuit
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
Electric Theory Test
60 min.
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
Evaluation
30 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
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Standard
1.7
Basic Maintenance Training
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21 March, 2016
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.
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Standard
1.8
Basic Maintenance Training
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21 March, 2016
BMT Electric Module Time Table
The order in which the elements of the Training Module are delivered may vary.
Lesson
1
Introduction
Element
1.1
1.2
1.3
1.4
1.5
1.6
2
3
Introduction to
Electricity
Alternating current
introduction
2.1
2.2
2.3
3.1
3.2
3.3
4
Electrical measuring
instruments
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
7
Personal Protective
equipment and tools
7.1
7.2
8
Prevention of
unexpected start-up
8.1
Safety instructions and
emergency procedures
Facilities
Introduction
Scope and main objectives
On-going assessment
Motivation
TOTAL
Direct current
Ohm’s Law
Appointed persons
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
Approximate
Duration
30 min.
90 min.
60 min.
90 min.
120 min.
Safety signs
TOTAL
Types of PPE
Types of tools and instruments
TOTAL
The importance of Lock Out
Tag Out
15 min.
45 min.
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Basic Maintenance Training
TOTAL
9
Components, symbols
and diagrams
10 Sensors
11 Electrical circuits
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
10.1
10.2
10.3
10.4
10.5
11.1
11.2
11.3
11.4
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
12 Electric Theory Test
12.1
Test
13 Evaluation
13.1
13.2
13.3
Summary
Evaluation
Certificates
GRAND TOTAL
Version 0:
21 March, 2016
45 min.
165 min.
225 min.
TOTAL
75 min.
TOTAL
60 min.
TOTAL
30 min.
1050 min.
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1.9
Basic Maintenance Training
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21 March, 2016
Elements, BMT Electric Module
Lesson 1
Introduction
ELEMENT 1.1 Safety instructions and emergency procedures
Instructors shall explain:
1.1.1
1.1.2
Safety instructions according to internal procedures
Emergency procedures and emergency exits in the localities the
Delegates can be expected to be located during the course
ELEMENT 1.2 Facilities
Instructors shall explain:
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
Instructors shall explain:
1.3.3
The programme of the BMT Module, including breaks and meal times
ELEMENT 1.4 Scope and main objectives
Instructors shall explain:
1.4.1
Scope and main objectives of this BMT Module
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ELEMENT 1.5 On-going assessments
Instructors shall explain:
1.5.1
1.5.2
The reasons for the on-going assessment
GWO Control Measures and their use
ELEMENT 1.6 Motivation
Instructors shall explain:
1.6.1
Lesson 2
The importance of personal involvement in the course
Introduction to electricity
ELEMENT 2.1 Direct current
Instructors shall explain:
2.1.1
2.1.2
2.1.3
2.1.4
Electrical current definition and units
The basic concept between the current flow and the resistance
Voltage definition and units
Resistance definition and units. Variable resistance (PT100-temp)
ELEMENT 2.2 Ohm’s Law
Instructors shall explain:
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
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ELEMENT 2.3 Appointed Persons
Instructors shall explain:
2.3.1
2.3.2
Lesson 3
Why it is important, that only instructed and appointed persons are
allowed to perform electrical work
This course will not make the Delegate an appointed (authorised) or
instructed persons
Alternating current introduction
ELEMENT 3.1 Alternating current
Instructors shall explain:
3.1.1
The theory behind alternating current
ELEMENT 3.2 Alternating current in the circuit diagram
Instructors shall explain:
3.2.1
The location of AC in a basic electrical circuit diagram
ELEMENT 3.3 Alternating current/direct current
Instructors shall explain:
3.3.1
Difference between alternating and direct current.
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Lesson 4
Basic Maintenance Training
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Electrical measuring instruments
ELEMENT 4.1 Symbols and settings on the Multimeter and the
Amp Clamp meter
Instructors shall explain and demonstrate:
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 Digital instrument/multimeter
Instructors shall explain and demonstrate:
4.2.1
The measurement of
(1) VAC and VDC
(2) A and mA
(3) Ohms/ continuity
Delegates shall demonstrate:
4.2.2
4.2.2
How to measure Volt, Amp and resistance using a multimeter
How to measure continuity using a multimeter
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Lesson 5
Basic Maintenance Training
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Electrical hazards
ELEMENT 5.1 Effect of the electric current
Instructors shall explain:
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
Instructors shall explain:
5.2.1
5.2.2
When and how a direct contact happens
When and how an indirect contact happens
Delegates shall explain:
5.2.3
5.2.4
Some examples of direct contact
Some examples of indirect contact
ELEMENT 5.3 Damaged cables
Instructors shall explain:
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
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ELEMENT 5.4 High voltage
Instructors shall explain:
5.4.1
5.4.2
5.4.3
The definition of high voltage (dependent on the country)
The possible hazards related to high voltage
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
Instructors shall explain:
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
5.6.2
5.6.3
The function and importance of protective earth
The function of the GFCI/RCD
The symbol of the GFCI/RCD
ELEMENT 5.7 Stored energy
Instructors shall explain:
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
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ELEMENT 5.8 Static electricity
Instructors shall explain:
5.8.1
Lesson 6
The danger of static electricity in connection with the blade
Safety signs
ELEMENT 6.1 Safety signs
Instructors shall explain:
6.1.1
6.1.2
The meaning of the different safety signs
Show examples of safety signs on different locations in the WTG
Delegates shall engage in discussion of:
6.1.3
Lesson 7
Different safety signs’ meanings
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
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ELEMENT 7.2 Types of tools and instruments
Instructors are to explain:
7.2.1
7.2.2
7.2.3
How to recognise tools suitable for electrical work (e.g. insulated tools)
Test instruments, leads and their categories
Calibration and visual inspection of test instruments and leads
Delegates shall engage in discussion of:
7.2.4
Lesson 8
How to identify the validity of tools
Prevention of un-expected start up
ELEMENT 8.1 The importance of Lock Out Tag Out
Instructors are to explain:
8.1.1
8.1.2
The importance of Lock Out Tag Out
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
Lesson 9
An example of the procedure for Lock Out Tag Out
Components and symbols
ELEMENT 9.1 Resistors
Instructors are to explain:
9.1.1
9.1.2
9.1.3
The function of resistors
The symbol for resistors
The position of resistors in a circuit
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ELEMENT 9.2 Batteries
Instructors are to explain:
9.2.1
9.2.2
9.2.3
9.2.4
The function of batteries
The symbol for batteries
The position of batteries in a circuit
The risks and hazards associated with stored energy
ELEMENT 9.3 Switches
Instructors shall explain:
9.3.1
9.2.3
9.3.3
The function of switches
The symbols for different switches
The position of switches in a circuit
ELEMENT 9.4 Contactors
Instructors shall explain:
9.4.1
9.4.2
9.4.3
9.4.4
Different contactors
The function of contactors
The symbol for contactors
The position of contactors in a circuit
ELEMENT 9.5 Relays
Instructors shall explain and demonstrate:
9.5.1
9.5.2
9.5.3
9.5.4
Different relays
The function of relays
The symbol for relays
The position of relays in a circuit
ELEMENT 9.6 Diodes
Instructors shall explain and demonstrate:
9.6.1
9.6.2
9.6.3
The function of diodes
The symbol for diodes
The position of diodes in a circuit
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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
9.7.2
9.7.3
The function of bridge rectifiers
The symbol for bridge rectifiers
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
9.8.2
9.8.3
9.8.4
The function of capacitors
The symbol for a capacitor
The position of capacitors in a circuit
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
Instructors shall explain:
9.9.1
9.9.2
9.9.3
The function of transformers
The symbol for transformers
The position of transformers in a circuit
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ELEMENT 9.10 Generators and motors
Instructors shall explain:
9.10.1
9.10.2
9.10.3
The basic function of generators and motors
The symbols of generators and motors
The position of generators and motors in a circuit
ELEMENT 9.11 Fuses and circuit breakers
Instructors shall explain:
9.11.1
9.11.2
9.11.3
9.11.4
9.11.5
The function of fuses
The function of circuit breakers
The symbol for fuses
The symbol for circuit breakers
The position of fuses and circuit breakers in a circuit
ELEMENT 9.12 Processor Control Systems
Instructors shall explain:
9.12.1
9.12.2
Lesson 10
The function of Processor Control Systems
The position of the Processor Control System in the circuit
Sensors
ELEMENT 10.1 Types
Instructors shall explain:
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
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ELEMENT 10.2 Wind sensors
Instructors shall explain:
10.2.1
10.2.2
10.2.3
10.2.4
The function of wind sensors
The symbol for wind sensors
The different types of wind sensors
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
10.3.2
10.3.3
The function of temperature sensors (PT 100 and thermistor)
The symbol for temperature sensors (PT 100 and thermistor)
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
Instructors shall explain:
10.4.1
10.4.2
The function of yaw sensors
The position of yaw sensors in a circuit
Delegates shall engage in discussions of:
10.4.3
The locations and functions of yaw sensors
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ELEMENT 10.5 Pressure sensors
Instructors shall explain:
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
Lesson 11
The locations and functions of the pressure sensors
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
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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
11.3.4
11.3.5
How to check continuity in an electrical circuit
How to measure voltage AC and DC in an electrical circuit
How to measure current in an electrical circuit
ELEMENT 11.4 The electrical WTG system
Instructors shall explain:
11.4.1
11.4.2
11.4.3
Lesson 12
A single line diagram for the main power components in a WTG
An overview of the auxiliary circuit in a WTG
An overview of the communications and controllers in a WTG
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
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Standard
Lesson 13
Basic Maintenance Training
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21 March, 2016
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.
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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
BMT Electrical Module
2.3
Session
Theory
Practical
Instructor – Delegate Ratio
1:12
1:6
Facilities
The full range of facilities shall be available during the training. The following facility criteria
shall be adhered to.
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2.4
Basic Maintenance Training
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21 March, 2016
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.
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2.6
Basic Maintenance Training
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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
UK – BS
USA – ANSI
Canada – CSA
Australia and New Zealand – AS/NZS
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.
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Basic Maintenance Training
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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.
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Basic Maintenance Training
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Control Measure
Name: __________________________________
Course: BMT Electrical Module
Date: ________
Scenario Organisation
Training Provider: __________________
Violation of
Assessment
Measures
0-2
Passed/
3 Failed
Instructor Remarks
Aware of personal and
group safety at all times
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
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Applies subject
knowledge correctly in
given scenario
Demonstrates
understanding of subject
Total Marks
0–9
10 – 27
Pass
Fail
Instructor: _____________________________________________________________
□ PASS
□ FAIL
The practical Assessment Measures Form is a final evaluation tool for the instructors to assess
Delegates during practical elements. It allows measurement of the number of violations in
regard to safety, competency, or attitude. It can be used as a progressive evaluation tool to
discuss the performance of a Delegate in guiding them to success and it also serves as
supporting documentation when a Delegate fails the Module.
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