Working on wind turbines presents a technical challenge and requires absolute discipline in terms of safety.
Hazards such as falls from height, risks associated with electrical installations, changing weather conditions and transport operations can have critical consequences for both people and infrastructure.
A very important tool for managing these risks is therefore the operating manual, a legally required normative document that precisely defines all aspects of working with energy equipment.
In the wind energy sector, where work often takes place over a hundred metres above the ground in unpredictable weather conditions, such documentation is essential for operational stability, providing a kind of roadmap that limits human error and clearly defines responsibilities.
Thanks to this documentation, every inspection, maintenance activity and emergency intervention is carried out according to standardised procedures that protect the health and safety of employees and safeguard the investment itself. A properly developed and rigorously applied instruction manual is not a formality, but a pillar of safety – without it, the reliability of wind turbines and entire farms remains illusory.
Wind turbine technician: what does working on wind turbines involve?
Entering the interior of a wind turbine is like stepping into a completely different world, where steel, height and energy converge at a single point and every technician’s movement matters.
It is, by definition, a dangerous job: working dozens of metres above the ground in narrow nacelles or confined spaces where there is no margin for error. This is why the applicable regulations are not an empty formality, but a shield that truly protects life.
On-the-job training, personalised task allocation, a carefully planned sequence of activities, and strict adherence to protective measures are the daily rituals of technicians, without which work cannot begin. Anyone entering a turbine must be aware of their tasks and the hazards in their environment, and how to react quickly in an emergency.
Mechanical, electrical and height-related hazards are omnipresent and real, but it is thanks to consistently followed procedures that wind farms can be places where technology meets safety, with risk – though it can never be eliminated – kept under control.
All activities inside technical equipment, from the nacelle to the tower space, may only be carried out on the basis of a written order or permit, which specifies the scope of activities, the method of supervision, and the persons responsible for safety.
This means that entry into confined spaces is not spontaneous and must be approved by a qualified employee each time.
As Dr Michał Przygoda points out, ensuring constant safety is equally important. In practice, the minimum working team requires someone to monitor activities inside. In the case of high-risk work, such as maintaining electrical equipment in the nacelle, two technicians must work inside and a third must secure from the outside.
Weather conditions are also critical. Regulations and manufacturers’ recommendations define wind speed limits beyond which work becomes too risky. Access to the lower platform is permitted up to 25 m/s and to the nacelle up to 20 m/s. However, the operation of hoists or transport equipment requires stricter limits of below 10 m/s.
Maintenance work carried out inside and outside the tower is performed at wind speeds between 12 and 20 m/s. Any sudden gust that could threaten the structure’s stability is a signal to stop work immediately and evacuate the team.
This system of formal permits, constant supervision, and strict environmental restrictions establishes a solid foundation for safety when working on wind turbines, where virtually no margin for error exists.
Risk analysis in wind turbine operation clearly indicates that health and safety procedures should be treated as an integral component of the energy asset management system rather than as mere formalities.
Written permits, the proper organisation of service teams, and the ongoing monitoring of weather conditions create a multi-layered security structure designed to reduce accidents and economic losses. A key element is the absolute prohibition of work during storms, regardless of their extent, because the dangers associated with lightning strikes pose systemic risks.
Neglecting this rule can result in loss of health or life, as well as destabilising the energy generation process and increasing repair and downtime costs. In this context, compliance with health and safety rules is critical, determining both operational safety and the long-term competitiveness of the industry, as emphasised by Michał Przygoda.
Risk and protection in live maintenance work
Operating electrical equipment in wind turbines requires strict adherence to the procedures set out in PN-EN 50110-1 and internal operator instructions.
Michał Przygoda points out that all activities must be carried out by teams of at least two people, including employees with valid energy qualifications.
The presence of a second technician serves as a safety measure, enabling immediate intervention in the event of electric shock or electric arc burns. Live work requires the use of certified insulated tools and protective clothing with electric arc resistance properties.
The use of any conductive elements, including metal clothing or accessories, is prohibited. Environmental conditions in the switchboard area must be checked – the presence of water eliminates the possibility of carrying out maintenance work due to the risk of reduced insulation resistance and uncontrolled breakdowns. Regular insulation resistance measurements, electric shock protection tests and detailed visual inspections of the cables’ condition are an integral part of the procedure. The cables must be taken out of service in the event of insulation damage, overheating or wear.
Rules for using internal ladders when working inside a wind turbine tower
Entering the interior of a wind turbine tower is not only a physical challenge, but also a test of safety discipline that must not be underestimated, emphasises Michał Przygoda.
Climbing to a height of several dozen metres in a confined space requires technicians to be fully focused and strictly adhere to procedures, as any mistake could result in a serious accident.
The most important element is the proper use of the safety system. According to the standards, a maximum of two people can be attached to one rope, but never on the same section of the ladder. This guarantees a safety margin in the event of a failure.
In practice, this means maintaining safe distances and coordinating activities precisely, supported by efficient communication within the team.
Equally important is the organisation of equipment transport: a person carrying a load always moves in a strictly defined position within a column, which reduces the risk of snagging on the structure and ensures smooth operation. It is also crucial to remember to close the manholes at each level, as open passages pose a real risk of falling in conditions of limited visibility and fatigue.
The final few metres of the descent are particularly treacherous as routine and haste can lead to the premature unclipping of the self-locking safety device, which statistically results in the highest number of incidents. Therefore, the principle of continuous safety until reaching the final landing is fundamental to working at height.
Experience from daily maintenance practice clearly confirms that following these rules protects the lives and health of technicians and builds trust and a sense of security within the team. This allows them to perform their tasks more efficiently with greater confidence and less psychological stress.
A section of a service ladder with a closed hatch inside a wind turbine tower is one of the simplest yet most telling examples of how effective health and safety measures are based on consistently implementing seemingly obvious rules. Closing the hatches while climbing eliminates the risk of tripping or falling uncontrollably to lower levels of the structure, which is critical to the health and safety of technicians working at height. At the same time, this same feature protects people below by preventing tools or small installation parts from falling accidentally. In practice, this solution is not an addition, but an integral part of the rigorous health and safety procedures that define the work culture in the wind energy industry.
A self-locking device is an indispensable element of the personal safety system used when working on wind turbines, providing continuous protection against falls when moving along a ladder. Its fully automatic mechanism enables it to move smoothly along the rope behind the worker, immediately initiating a lock in the event of a sudden load. This guarantees the service technician uninterrupted protection along the entire length of the ladder while maintaining complete freedom of movement — an optimal compromise between safety and ergonomics in a highly reliable environment.
Summary
Wind energy is currently the showcase of the modern economy, but its development cannot obscure the fact that it is driven by people who face unique challenges and hazards in their daily work. Falls from height, electric shocks, unpredictable weather conditions, contact with chemicals and working in isolation are all part of technicians’ reality, and their safety must be prioritised.
While regulations and standards are essential, it is the safety culture and awareness of employees that determine whether the system actually works. Only when compliance with health and safety rules becomes a natural reflex rather than a tick-box exercise can we talk about the real protection of life and health.
Developing wind energy is not just about building more turbines; it is also about investing in the people who install and service them. They are the sector’s most valuable resource. Therefore, every investment decision should be accompanied by the question: does concern for human safety go hand in hand with technological progress? Without this balance, green energy may never be truly safe.
This text is based on an article by Dr Michał Przygoda, published on the dolinaoze.pl website, entitled ‘Risk at height: how to work safely in wind energy’.
