Post-incident inspection guide & report SQYFlex Blue
Procedures for inspecting the SQYFlex Blue platform following an operational incident. This revision covers Chapter 1 — Tagline overload inspection. Further chapters covering other incident types will be added in future revisions.
| Doc id:205-WI-3095 | Document typeWork Instruction | Owner:Philip Fitzgerald Williamson |
| Date:17/06/2026 | Document titlePost incident inspection guide & report - SQYFlex Blue | Version:1.0 |
- 1. Introduction
- 1.1 Abbreviation
- 2. Disclaimer
- 3. Protective equipment
- 4. Risks and hazards
- 5. Tools required
- 6. Chapter 1 – Tagline overload inspection
- 6.1 When to use this chapter
- 6.2 Background
- 6.3 How to use this chapter
- 6.4 Inspection checklist
- 6.5 Recording findings
- 6.6 Additional inspection items
1. Introduction
The purpose of this work instruction is to provide safe and secure instructions describing the procedures that shall be carried out to inspect the SQYFlex Blue platform, hereinafter referred to as “the platform”, following an operational incident. This guide is organised into chapters, with each chapter covering a specific incident type. The current version of this guide includes the following chapter: Chapter 1 – Tagline overload. Further chapters covering other incident types, such as heavy landings and tower strikes, will be added to this guide in future revisions. If a component or function on the platform cannot be deemed to be in good and well-functioning condition in accordance with requirements in the applicable steps, then the platform may not be taken into operation, and supervisor must be informed immediately.
This guide is to be used following any of the incident types covered in the chapters of this document. Refer to the relevant chapter for the specific triggers requiring that chapter’s inspection.
This work instruction is only applicable for the SQYFlex Blue platform, and the document shall only be used as a guide for the list of components and areas to be inspected following an incident. The document shall not be seen as an exhaustive list containing all relevant information. Additional inspection items identified following platform-specific workshop investigations will be incorporated into future revisions of the relevant chapter.
This work instruction shall be read in conjunction with the following associated documents for ascertaining the various risks and hazards involved with the platform:
- SQYFlex Blue User Manual
- Tagline – SQYFlex Blue
- Rigging – SQYFlex Blue
- User manual for ActSafe
1.1 Abbreviation
| Abbreviation | Explanation |
|---|---|
| BSO | Block stop |
| PPE | Personal protective equipment |
| RCCB | Residual current circuit breaker (HPFI) |
| TGI | Tower guide interface |
| TGS | Tower guide system |
2. Disclaimer
Operators may not operate the platform, unless they have read and understood the information in this work instruction. PP Techniq A/S believes the information in this work instruction provides an accurate illustration of the process to be followed for inspection of the equipment before use. However, PP Techniq A/S cannot, without PP Techniq A/S’ written consent, be held liable for injury, death, loss, damage, or expenses, whether direct, indirect or consequential, including, but not limited to, loss of use, revenue, profit or production, or increased cost of operation, or for any charges or expenses of any nature incurred in connection with the use of the platform.
This is the master document in English. Translations of the manual into other languages are done to the best of our knowledge. PP Techniq A/S assumes no liability for translation errors. If there is anything in the work instruction that is not clear, or cannot be properly understood, then PP Techniq A/S shall be contacted. PP Techniq A/S reserves the right to amend and improve the work instruction as they see fit, although it is in its present form deemed adequate. Only trained and certified technicians shall be allowed to operate the platform. Technicians need to attend and pass PP Techniq’s operator training (provided by PP Techniq A/S) to meet this requirement.
3. Protective equipment
Personnel working with or close to the platform shall always use the safety equipment illustrated in Table 1. The local authorities, wind turbine manufacturer or owner may stipulate further requirements. All safety equipment must be inspected and serviced in accordance with local legislation and requirements.
 |
Non-slip safety footwear |  |
Protective gloves (Required during assembly and handling of wires) |
 |
Protective helmet |  |
Safety harness (Required when platform is suspended) Harness Fall Arrester SLR - Self Retracting Lifeline (Yo-Yo) |
 |
Hi-Vis Vest and/other Hi-Vis clothing |  |
Use safety goggles |
4. Risks and hazards
Risks and hazards related to specific operations will be presented throughout this work instruction using the callouts presented in Table 2.
Important information related to the platform.
If caution is not adhered to, then it may cause minor or moderate injury, and damage to platform.
If warning is ignored, then it can cause death or serious injury.
If danger is not avoided, then it will cause death or serious injury.
5. Tools required
PP Techniq A/S recommends using the equipment listed below in Table 3 or similar, to be able to conduct the post-incident inspection in a safe and controlled manner. The list of tools is not exhaustive in nature and installation personnel can use additional tools based on site conditions and local regulations, if any.
| Item description | Specification | Quantity |
|---|---|---|
| Two-step ladder |  |
1 |
| Rig/self-braking descender |  |
1 |
| Pulley wheel |  |
2 |
| Rope grab |  |
1 |
| Rope | 10 meter | 1 |
| Open loop sling | 0.5 meter | 2 |
| Carabiner | — | 4 |
| Hook&Moor | — | 1 |
6. Chapter 1 – Tagline overload inspection
6.1 When to use this chapter
This chapter shall be used to inspect the platform following any event in which the recorded tagline load on either the port or starboard load cell exceeded 360 kg, the permitted maximum tagline load for the SQYFlex Blue platform. Under normal operating conditions, load cell values are expected to remain within the range of 200–300 kg during active use.
If telemetry indicates that a tagline overload has occurred, the platform must not be returned to service until the inspection in this chapter has been completed and any defects identified have been assessed and cleared by a supervisor or engineer.
Do not operate the platform under load until this inspection is complete. If any item in this chapter is found to be outside acceptable limits, the platform must be taken out of service pending engineering review.
6.2 Background
Diagnostic testing has established the likely damage mechanisms associated with tagline overload. During controlled workshop testing, tagline loads were increased progressively up to 450 kg. The following effects were observed:
- At 450 kg, the TGS motor brake struggled to engage, causing the TGS re-alignment function to malfunction. Normal re-alignment function was only restored after the tagline load was reduced to the 200–300 kg range.
- Physical deformation of the lower TGS pulley carriage was observed. The carriage deformed under extreme load, causing the TGS cable on the tagline side to become dangerously taut.
Given that recorded overload events may exceed the loads applied during workshop testing, the inspection items in this chapter focus on the components most likely to be affected.
6.3 How to use this chapter
The inspection checklist in this chapter is organised by assembly area. For each item, this chapter specifies the component to be inspected, what to look for, why the check is relevant, and a priority level:
- Critical – the platform must not be returned to operation until the item has been inspected and any defect resolved.
- High – the item should be resolved at the earliest opportunity.
- Standard – the item should be documented and monitored.
Technicians shall photograph all findings, record the platform identification and the location of each finding, and return completed records to the responsible engineer in accordance with Section 6.5 of this chapter. Items marked Critical that are found to have a defect must be reported immediately.
6.4 Inspection checklist
The following items shall be inspected following a recorded tagline overload event.
The TGS pulley carriage and cable are safety-critical components. Deformation or damage to these components, if not identified and rectified, can lead to failure of the TGS re-alignment system during operation.
6.4.1 TGS pulley carriage assembly
| Ref | Component | What to inspect | Why | Priority |
|---|---|---|---|---|
| T.01 | TGS lower pulley carriage | Inspect for visible deformation, bending, or cracking of the carriage body and mounting brackets. Compare geometry against an unloaded reference unit if available. | Direct failure mode observed in workshop testing at 450 kg tagline load. | Critical |
| T.02 | TGS pulley wheel | Check the pulley wheel for flat spots, cracking, deformation of the rim, or seized or rough rotation. Spin the wheel by hand and check for uneven resistance. | Deformation of the carriage changes the load angle on the pulley wheel, potentially causing localised overloading of the wheel rim. | Critical |
| T.03 | TGS cable – tagline side | Inspect the full accessible length of the TGS cable on the tagline side for kinking, birdcaging, broken strands, or evidence of having been pulled over a deformed edge. | Workshop testing showed this cable became dangerously taut when the carriage deformed. Kinking or strand damage significantly reduces safe working load. | Critical |
| T.04 | TGS cable – full run | Inspect the entire accessible TGS cable run, including anchor points and terminations, for signs of strain, displacement, or damage. | Asymmetric loading between the left and right load cells can subject the cable to uneven tension across its run. | High |
| T.05 | Pulley carriage mounting fasteners | Check all bolts, pins, and fasteners on the pulley carriage assembly for shear damage, elongation of holes, or loosening. Verify torque where accessible. | Carriage deformation introduces shear and bending forces into the fastener group beyond design intent. | Critical |
| T.06 | Pulley carriage pivot and articulation points | Inspect all pivot pins, bushings, and articulation joints for deformation, seizure, cracking, or displacement from designed position. | Extreme load concentrates stress at articulation points. If pivot geometry has shifted, the assembly will not return to correct alignment under normal use. | High |
6.4.2 TGS motor and brake
| Ref | Component | What to inspect | Why | Priority |
|---|---|---|---|---|
| M.01 | TGS motor brake – function test | With the platform in a safe, supervised condition, test the TGS motor brake by running a re-alignment cycle under a known moderate tagline load, within the permitted range. Verify that the brake engages cleanly and holds position without drift. | Workshop testing at 450 kg demonstrated the motor brake struggled to engage. The brake mechanism may have been damaged or its engagement characteristics altered. | Critical |
| M.02 | TGS motor brake – physical inspection | Visually inspect the motor brake assembly for signs of heat discolouration, mechanical wear, or deformation. Check brake pad or disc condition where accessible. | A brake that struggled under load may show evidence of slipping, excess heat generation, or accelerated wear. | High |
| M.03 | TGS re-alignment function | With the platform in a safe, supervised condition, test the full TGS re-alignment cycle. Verify that the left and right TGS respond symmetrically and that the function completes without error or manual intervention. | Malfunction of the re-alignment function was directly observed in workshop testing at 450 kg. This function is safety-critical for platform stability. | Critical |
| M.04 | TGS extension disparity | Measure and record the left and right TGS extension lengths. Note any difference (disparity) between the two sides. | The overload event may have resulted in a permanent extension disparity that was not self-corrected. | High |
When inspecting load-bearing components, give particular attention to the side of the platform on which the higher load was recorded, as this side is more likely to show signs of overload damage.
6.4.3 Tagline attachment and load path
| Ref | Component | What to inspect | Why | Priority |
|---|---|---|---|---|
| L.01 | Tagline attachment points – port side | Inspect all load-bearing components in the port-side tagline load path for deformation, cracking, elongation of holes, or displaced hardware. Pay particular attention to shackles, pins, and brackets. | Both sides must be inspected. Give priority attention to whichever side recorded the higher load during the overload event, as that side is more likely to have absorbed a disproportionate share of the force. | Critical |
| L.02 | Tagline attachment points – starboard side | Inspect all load-bearing components in the starboard tagline load path using the same criteria as item L.01. | Both sides must be inspected. Give priority attention to whichever side recorded the higher load during the overload event, as that side is more likely to have absorbed a disproportionate share of the force. | Critical |
| L.03 | Load cell – left | Inspect the left load cell body, mounting, and cable connections for physical damage. Note any cracking, deformation, or loose connections. | Both load cells must be inspected. A load cell subjected to extreme overload may give inaccurate future readings even if undamaged externally. Give priority attention to the cell on whichever side recorded the higher load. | Critical |
| L.04 | Load cell – right | Inspect the right load cell body, mounting, and cable connections for physical damage, disconnection, or moisture ingress. | Both load cells must be inspected. A load cell subjected to extreme overload may give inaccurate future readings even if undamaged externally. Give priority attention to the cell on whichever side recorded the higher load. A non-responsive load cell may indicate a sensor fault or wiring damage caused during the overload event. | Critical |
6.4.4 Platform structure
| Ref | Component | What to inspect | Why | Priority |
|---|---|---|---|---|
| S.01 | Platform frame – TGS mounting area | Inspect the platform structural frame in the area of the TGS mounting for cracking, deformation, or weld failure. Use a torch and, where necessary, remove covers for access. | The TGS assembly transfers tagline loads into the platform frame. Sustained overload introduces bending and shear forces into the surrounding structure. | High |
| S.02 | Platform frame – general visual | Walk the full accessible perimeter and underside of the platform, looking for visible cracking, buckling, or deformation that was not present at the last inspection. | Comprehensive visual check to identify any structural effects of the overload not covered by specific component checks above. | Standard |
| S.03 | Actuator brackets | Inspect all actuator brackets for displacement, deformation, cracking, or loosening from their mounted position. Check that bracket alignment and fastener torque are within specification. | Actuator brackets transfer operational loads into the platform structure. Overload can displace or deform brackets, compromising actuator function and structural integrity. | Critical |
6.4.5 Wind sensor
| Ref | Component | What to inspect | Why | Priority |
|---|---|---|---|---|
| W.01 | Wind speed and direction sensor | Inspect the anemometer for physical damage, loose wiring, or disconnection. Verify that the sensor returns valid wind speed and direction readings. | A wind sensor that records zero values throughout an overload event indicates a monitoring gap. Without a functioning wind sensor, it is not possible to confirm whether the overload occurred within permitted wind conditions. | High |
6.4.6 DOF beam assembly
| Ref | Component | What to inspect | Why | Priority |
|---|---|---|---|---|
| D.01 | DOF beam assembly | Inspect the full DOF beam assembly for deformation, cracking, or displacement. Check the tension of the DOF wire and confirm it is within specification; inspect the wire along its full accessible length for kinking, bird-caging, or broken strands. | The DOF beam and wire are load-bearing components in the platform’s degree-of-freedom mechanism. Overload can deform the beam or alter wire tension, compromising safe operation. | Critical |
6.5 Recording findings
For each item inspected, technicians shall record the following within their inspection report:
- Platform identification
- Inspection item reference (for example T.01)
- Date and time of inspection
- Inspector name
- Finding: pass, defect found, or unable to inspect (with reason)
- Description of any defect, including location and severity
- Photographs – a minimum of one photograph per defect found, labelled with the item reference
All completed records shall be returned to the responsible engineer. Any item marked Critical for which a defect is found must be reported by telephone immediately; do not wait for written records to be submitted.
6.6 Additional inspection items
This section will be updated following workshop investigations of platform-specific overload events. Additional inspection items identified during those investigations will be incorporated into future revisions of this chapter. Technicians should confirm they hold the current revision of this chapter before commencing inspection.