BOLTED JOINT ASSEMBLY WIND ENERGY FIELD SERVICE TECHNICIANS 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly BOLTED JOINT ASSEMBLY WIND ENERGY FIELD SERVICE TECHNICIANS INTRODUCTION This course is focused on the practical principles of assembly, not the design of bolted joints. It is targeted to field service technicians, supervisors, engineers and others who are responsible for quality in bolting and who need to acquire or refresh their knowledge of best practices so that they can better assess performance and achieve the results they seek. A one-day course for mechanics is also available.

1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly The following material is intended to make you aware of the commonly accepted and recognized principles and methods used in assembling bolted joints. However, every possible application of these methods cannot be foreseen and these general guidelines do not supersede any other applicable rules or regulations. ALWAYS FOLLOW CURRENT COMPANY AND SITE SAFETY RULES AND PROCEDURES WHEN PERFORMING ANY OF THE WORK DESCRIBED IN THIS PRESENTATION. The authors and sponsors of this course have no control over, and assume no responsibility for any damage, injury or work interruptions due to any person’s use of, or reliance upon these generally accepted methods and principles. > No course can cover all possibilities and address all problems. The key is to know what to look for, and where to go to get the answers. Hopefully that is what you will take away from this course.

But you might be surprised about how much there is to know! 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly We have all grown up around nuts and bolts and don’t give them much thought. Since we were old enough to remember we have always been around nuts and bolts. But you might be surprised by how much there is to know. But you might be surprised about how much there is to know! FOR EXAMPLE…

MANY INDUSTRIES - HUNDREDS OF APPLICATIONS 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly MANY INDUSTRIES - HUNDREDS OF APPLICATIONS You may become involved in the maintenance and overhaul of hundreds of different types of equipment, but although the machinery may be different, with regard to bolting there are common principles and procedures you can apply across the board. >

NO MATTER HOW BIG AND COMPLEX THE MACHINERY GETS... 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly NO MATTER HOW BIG AND COMPLEX THE MACHINERY GETS... AT ITS HEART, HOLDING EVERYTHING TOGETHER IS THE HUMBLE LITTLE BOLT But at the heart of the matter, holding everything together is the humble little bolt. > Let me introduce you to Bubba the bolt! Bubba will help us highlight some important principles and help us with a few demonstrations as we proceed.

WHY SHOULD WE CARE ABOUT BOLTED JOINT ASSEMBLY FOR THE WIND ENERGY INDUSTRY? 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly BOLTED JOINTS ARE EVERYWHERE… TOWERS AND TURBINES MACHINE JOINTS COUPLINGS AND ALIGNMENT

THE AVERAGE WIND TOWER HAS OVER… 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly 500 CRITICAL BOLTS! BEDPLATE BOLTS GENERATOR COUPLING GEARBOX BEARINGS MAIN BEARINGS YAW BEARING BLADE BEARINGS ROTOR TO MAIN SHAFT TOWER TO NACELLLE TOWER BOLTS BLADES TO HUB The simplest reason is that the average modern wind tower has over 1000 bolts each of which is critical to its stability and performance over its planned 20 year life cycle! From the base of the tower, to the turbine, to anchoring each of the huge blades to its hub, the integrity, efficiency and safety of the structure depends on every single fastener doing its job. The failure or loosening of a single bolt could begin a chain reaction that could cripple the entire system.

AND WHEN MACHINES BEGIN TO COME APART THINGS CAN GET EXCITING IN A HURRY! 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly

BOLTING IS ALWAYS IN THE CRITICAL MAINTENANCE PATH… 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly BOLTING IS ALWAYS IN THE CRITICAL MAINTENANCE PATH… DISASSEMBLY OVERHAUL RE-ASSEMBLY EVERY HOUR OF DOWNTIME COSTS THOUSANDS OF DOLLARS IN LOST GENERATION $

TRAINED DEDICATED PEOPLE 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly Getting things RIGHT When you’re working at HEIGHT.. Safely And doing it DEMANDS Wind towers are inherently dangerous places to work. What, on the ground might be a simple task, becomes much more challenging 300 feet in the air. In addition to the problems of working at height, there are confined spaces, restrictive harnesses, high electrical voltage, confined spaces, and isolation from help if an emergency does occur. People must learn to work with and depend upon their buddy because their safety and very life may depend upon carefully following the established operating procedures and doing the job right the first time so that someone else is not put at risk to fix a problem you left undone. TRAINED DEDICATED PEOPLE Wind Towers Are Not For Rookies!

TRAINING BENEFITS EVERYTHING IT TOUCHES 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly THE DOOR TO THE SAFETY, QUALITY AND EFFICIENCY OPENS WITH A KEY! TRAINING TRAINING IN THE WORKPLACE IMPROVES BOTH THE JOB AND THE PEOPLE QUALITY, EFFICIENCY, SAFETY AND WORKER SATISFACTION ALL IMPROVE TRAINING BENEFITS EVERYTHING IT TOUCHES Training is the key to safety, to quality, and to efficiency. Both the job and the people are made better when they get an opportunity to learn how to improve their skills. People feel good about themselves and stay longer with an employer who expresses enough confidence in them to spend time and money to train them. Training benefits everything it touches.

Critical learning goals for bolting personnel: 1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly PRINCIPLES OF JOINT RELIABILITY BASICS OF TORQUE AND TENSION FACTORS THAT AFFECT THE ACCURACY OF LOAD AND HOW TO ACHIEVE YOUR GOAL SAFE OPERATION AND HANDLING OF INDUSTRIAL BOLTING TOOLS WHY BOLTS COME LOOSE AND WHAT TO DO ABOUT IT EXAMPLES OF TYPICAL WIND BOLTING TASKS PRACTICAL APPLICATION – NOT JUST TALK! Here are some of the key subjects we will explore in this course.

1 BOLTING ASSEMBLY TRAINING - INTRODUCTIONNotes from the Training Course on Bolting Assembly LET'S GET STARTED! So let’s get started!