O&M Training Playbook - Robert J. Allenrobertjallen.yolasite.com/resources/Desktop Publishing.pdf · 2012. 9. 25. · GE Energy | O&M Training Playbook (06/2012) 1-1 1 Prologue This

O&M

Training Playbook

©2012, General Electric Company. All rights reserved.

GEA19964 (05/2012)

GE EnergyPower Generation Services

O&M Training Playbook

1 Prologue

1 Prologue

1-1GE Energy | O&M Training Playbook (06/2012)

Prologue1

This Global O&M Services Training Playbook describes the basis for planning and executing an initial and continuing training program for most O&M plant personnel. It focuses on establishing a training process that continuously provides the knowledge and skills all personnel need to perform their jobs in a safe and effective manner.

The goal of this Playbook is to drive a standard training approach for all O&M plant personnel including site leaders, operators and technicians. Their skills, knowledge and abilities enable O&M sites to be operated and maintained in a reliable and efficient manner. The implementation of this O&M Training Playbook is driven by business leaders who understand the importance of Training as a key business differentiator and competitive advantage.

Identifying training requirements and planning and executing training is a continual process. It is only through the participation and commitment of all plant personnel that a training function can be effective. The Plant Leadership team is responsible for enforcing and supporting the participation and commitment from all. This Playbook emphasizes these responsibilities and describes how the Plant Leadership drives their own training programs to fulfill their own specific needs.

This Playbook consists of:

• Training programs for the plant leadership team

• General guidelines to establish and conduct training at a typical O&M site

• A series of position-specific training programs focusing on operator and technician training

These training programs reflect the fact that plant leadership positions have mostly decision-driven responsibilities while operators and technician positions are more task-driven. Management programs focus on technical and process knowledge with special emphasis on leadership development while operator and technician programs focus on knowledge and job duties with strong emphasis on task execution capability verification.

The ultimate goal of this Playbook is to establish a training program that will develop world-class plant managers, operators and technicians. This can only be accomplished by support and involvement of all O&M business leaders, including all Headquarters personnel, Region and Plant Managers.

2 Plant Manager

2 Plant Manager Training Guidelines and Qualifications1.0 Purpose and Scope

2.0 Definitions

3.0 Roles and Responsibilities3.1 O&M Training Manager3.2 Region Manager3.3 Mentors3.4 Plant Manager Candidate

4.0 Policy

5.0 Training Process5.1 Planning and Design5.2 Curriculum Development5.3 Major Training Categories5.4 Execution5.5 Training Exemption Requests5.6 Continuing Training5.7 Training Review

6.0 Management Review Requirement Summary

7.0 References

Attachment 1 - Plant Manager Curricula

Attachment 2 – Plant Manager Qualification Cards

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Plant Manager Training Guidelines and Qualification Purpose and Scope

GE Energy | O&M Training Playbook (06/2012)

2

1.0 Purpose and ScopePlant Managers provide key value for the Global Operations and Maintenance Services business and its customers. Their technical knowledge, leadership and business acumen are fundamental to the success and profitability of GO&MS contracts around the world.

The purpose of this Work Instruction is to establish and maintain this standard of excellence through Plant Manager (PM) training and qualification. The work instruction ensures PMs attain and maintain the knowledge, skills, and abilities required to perform their roles and responsibilities in an effective manner.

This training program applies to all Plant Managers at any GE O&M plant.

2.0 Acronyms and Definitions

CSA Contractual Services Agreement

DOE Department of Energy

EHS Environmental Health & Safety

FERC Federal Energy Regulatory Commission

GO&MS Global Operations & Maintenance Services

myLearning GE Energy Corporate Learning Management System

NERC North American Electric Reliability Corporation

OJT On the Job Training

OSHA Occupational Safety and Health Administration

PGS Power Generation Services

PM Plant Manager

QAP Quality Assurance Procedure

Qualification Business acknowledgement that an employee has fulfilled all training requirements defined for employee’s role or position

RBM Reliability Based Maintenance

TRB Training Review Board

3.0 Roles and Responsibilities

3.1 O&M Training ManagerThe role of the O&M Training Manager is to establish and administer, with the concurrence of the GO&MS Operations Leader, a formal program for training and qualification. It is their responsibility to:

• Revise and update this document as necessary.

• Establish criteria by which experienced candidates may be exempted from specific portions of the training program.

• Provide and maintain a list of knowledge requirements for all subjects in the training program.

3.2 Region ManagerThe role of the Region Manager is to evaluate and identify training and developmental needs for all PMs in their region. It is their responsibility is to:

• Advise and approve the program established by O&M Training Manager.

• Designate certified PMs under their direction to serve as mentors for PM qualification candidates as needed.

Plant Manager Training Guidelines and Qualification

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Policy


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• Determine, with the assistance of the O&M Training Manager, from which topics of the formal training program experienced candidates may be exempted.

• Monitor execution of the training plan, support the development process, and ensure PM candidates complete the training curriculum.

• Serve as instructors as needed.

3.3 MentorsMentors are PMs appointed at the discretion of their respective Region Manager to assist with on-the-job training of PM qualification candidates. Their responsibilities may include:

• Serving as Instructors for the formal training program as requested.

• Creating training material for the training program when assigned to do so by their Manager.

3.4 Plant Manager CandidatePMs seeking qualification must satisfactorily complete all phases of the Training Program as specified in this document within 24 months of being assigned to the curriculum.

4.0 PolicyThe training and qualification process is ongoing and continues past initial qualification. The training curriculum is updated as needed to reflect changes in business tools, processes and systems.

PMs newly assigned to their position must complete their initial training and qualification process within 24 months of being assigned to the curriculum. After completing initial qualification, PMs must complete all newly assigned training within the prescribed time to maintain their qualified status. This is referred to as Continuing Training.

Plant Managers who do not satisfactorily complete their initial training and qualification per requirement guidelines, and who do not annually maintain their qualified status as described in this document will be evaluated commensurate with their annual performance goals and objectives.

5.0 Training ProcessPlant Managers manage a highly technical environment, and are responsible for the overall performance of the plant from a financial, operational and regulatory perspective. They are responsible for the performance of personnel with a variety of backgrounds. They’re also required to manage their O&M contract in a profitable manner.

PMs share and delegate responsibilities with all plant personnel, including engineers and technicians. It is the PM’s responsibility to lead this team to a high level of performance. The overall responsibility for plant performance and contract profitability falls on PMs. The PM training program must address the breadth of these responsibilities.

5.1 Planning and DesignTable 1 indicates the terminal training objectives with respect to the PMs main role and responsibilities.

Table - 1

Responsibility Category Terminal Training Objective

Contract Management Understand the scope and content of their O&M contract. Effectively fulfill all contract requirements. This includes negotiation of concessions and extra work orders.

Contract Financials Manage and drive all financial aspects such as budgets, costs & billing and margin review. Track financial health of their contract to support contract profitability.

Contract Operations Execute contract activities and functions such as outage planning, customer reporting and customer and personnel meetings to fulfill contract requirements.

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Plant Manager Training Guidelines and Qualification Training Process


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Stakeholder Relations Manage customer and labor relations. Manage & Improve personnel performance by effectively leading and developing their overall skills and technical knowledge.

GE Internal Processes Manage internal procedures and processes with other GE P&L’s. Implement and support Policies 5.0 & 6.0 and Enterprise Resource Planning (ERP) process.

Law & RegulationsUnderstand scope and requirements of legal regulations defined by entities such as DOE, FERC, NERC, OSHA, etc. and how these regulations impact plant operations and maintenance activities. Drive the fulfillment of all these requirements.

Plant MaintenanceUnderstand and lead plant maintenance activities to improve plant overall reliability and availability. Ensure appropriate usage of CMMS among all plant personnel. Lead and support implementation of Reliability Based Maintenance (RBM).

Plant Operations Understand and lead plant day-to-day operations. Drive consistent usage of plant operational procedures. Promote collaboration between the operations and maintenance teams.

Project ManagementManage the execution of all plant upgrades and system improvements. Understand and apply tools and methods for effective project management so that these upgrades are performed on-time and within budget.

Technical KnowledgeUnderstand the design basis and basic functionalities of all plant equipment & systems. Drive plant operational efficiency, Evaluate the impact and feasibility of new power plant technologies.

Power Market Understand power markets and how to make their plant more competitive and cost effective.

The training program and courses are derived from task categories described in Table 1. These task categories are reviewed every three years as a minimum to keep the training program up-to-date with PM changing roles and responsibilities. These major responsibility categories are grouped into four training areas: Technical, Business Acumen, Leadership and On-the-Job Training as described in Curriculum Development.

5.2 Curriculum DevelopmentFour curriculum tracks have been established to improve training efficiency. These tracks are based on the different plant technologies that PMs manage for the GO&MS business. The track approach to the curricula lets PMs focus their training effort on the concepts and content most applicable to their sites.

The four curriculum tracks are:

• O&M PM Qualification – Heavy Duty Gas Turbine Combined Cycle.

• O&M PM Qualification – Heavy Duty Gas Turbine Simple Cycle

• O&M PM Qualification - Aero Gas Turbine

• O&M PM Qualification - Non-Gas Turbine Power Plant

PMs that transfer to a new site with different technologies will be assigned the appropriate curriculum. Once the new training is assigned, the PM must complete it within 12 months.

5.3 Major Training Categories

All four tracks contain four major task categories.

• Technical TrainingThis provides knowledge and understanding of the functionality, operation and maintenance of GE-specific Gas Turbines, Steam Turbines and Generators. It also covers Balance-Of-Plant (BOP) equipment. For the latest list of Technical courses, see Attachment #1.

Plant Manager Training Guidelines and Qualification

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Training Process


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• Business AcumenThis non-technical training describes all internal GE processes, systems and tools PMs use to perform major contract tasks. These include but are not limited to warranty management, contract management, customer management, and sales and service business processes. It also includes contract margin review, sourcing and billing processes, etc. For the latest list of Business Acumen courses, see Attachment #1.

• Leadership TrainingPMs need very strong communication, team performance and technology-driven leadership skills to succeed in an environment with constant interaction between man and sophisticated machinery and where customers are vigilant of all aspects of contract fulfillment and delivery. Leadership training enables PMs to support key business initiatives, keep pace with changing business requirements and model GE values. It also enables PMs to manage customer relations, labor relations and personnel performance at their sites. For the latest list of Leadership Training courses, see Attachment #1.

• On the Job Training (OJT)This covers aspects of the training that are most effectively delivered via one-on-one interaction with a mentor. This training is structured as a list of PM tasks and activities that, due to their scope and content, do not require classroom or computer-based sessions. OJT includes a variety of tasks from technical to business processes.

Mentors ensure all OJT tasks are completed successfully by the PM candidate. Mentors are responsible for guiding PMs through the OJT list and signing off on all items as PMs successfully complete them. For the latest revision of PM OJT checklist, see Attachment #2.

5.4 Execution Candidates must successfully complete all modules of the training program to achieve qualification. Candidates must complete all of the above phases either by direct participation and approval, or by demonstrating competency in one or more areas and being granted exemption. See Training Exemption Requests. Note: Due to varying schedules and business needs, candidates may need to adjust the sequence of their training.

5.5 Training Exemption RequestsWhen a candidate possesses the knowledge and skills associated with any given training course or item, the candidate may be exempted from that area of training. The candidate must present objective evidence showing the candidate possesses the knowledge and skill. Objective Evidence may be presented in the form of training certificates, diplomas, myLearning records and other items. Resumes alone do NOT qualify as objective evidence.

Training Exemption Requests for selected items of the Qualification Program are submitted by the candidate and approved by the appropriate Region Manager and O&M Training Manager based on the objective evidence.

The Training Exemption request work flow (WF) process can be started from the PGS Training Community Support Central site under “Process” at:

http://supportcentral.ge.com/products/sup_products.asp?prod_id=10832

5.6 Continuing TrainingContinuing training topics are identified and added to the training curriculum as needed. All individuals assigned to the curriculum must successfully complete this new assigned training in order to maintain qualification.

5.7 Training ReviewAn O&M Training Review Board (TRB) evaluates training curriculum effectiveness.

Annually, at a minimum, the O&M Training Manager will chair a meeting with the GE Global O&M General Manager or designee, a Region Manager, and an incumbent PM. This review board will identify enhancements and modifications to the PM training curriculum such as:

• Program effectiveness

• Training content

• Continuing training topics

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Plant Manager Training Guidelines and Qualification Management Review Requirement Summary


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6.0 Management Review Requirement SummaryThe following management reviews must be conducted and documented.

[Table QAP 001-01] Management Review Requirement Summary

Frequency Responsiblitoy Item Notes

Annual PGS Quality Program Manager, Manager O&M TrainingReview this instruction for applicability.

Annual O&M Operations Leader Participate in Training Review Meeting

Annual O&M Operations Leader Conduct Training Review Meeting

7.0 References• GEEQMS 6.2.2, Competence, Awareness and Training

• O&M Quality Assurance Procedure 007 Staffing &Training

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Plant Manager Training Guidelines and Qualification2


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Attachment 1 – Plant Manager Curricula

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Plant Manager Training Curricula Training Courses:

Aero Combined CycleSimple Cycle

Non-Gas Turbine

Non-Technical Courses

GEE-ENG-TECH099-CS Outage Excellence

GEE-FIN-FIN005-CS Contractual Services Enterprise Resource Planning (CS ERP) Finance

GEE-IT-IM037-CS eWarranty

GEE-IT-IM041-CS ICAM for Users

GEE-QUAL-RCA-e GEE eRCA COURSE (Web, Pre-requisite)

GEPS-ENG-TECH013-CS Forced Outage

GEPS-ENG-TECH014-CS Red Flag Review

GEPS-FIN-FIN001-CS CS Financial Overview

GEPS-FIN-FIN012-CS Contract Payment Stream and Escalation

GEPS-FIN-FIN020-CS Margin Review

GEPS-FIN-FIN030-CS Invoicing and Billing Responsibilities of a Contract Performance Manager (CPM)

GEPS-HR-HR0010-CS Contract Performance Manager and Plant Manager Duties

GEPS-HR-HR001-CS Introduction To Contractual Services

GEPS-LEGAL-LEGAL001-CS Contractual Service Agreements

GEPS-LEGAL-LEGAL003-CS Insurance Considerations for Contracts

GEPS-LEGAL-LEGAL005-CS Contract Performance and Usage

GEPS-LEGAL-LEGAL007-CS Executing Insurance Provisions - Global

GEPS-LEGAL-LEGAL008-CS Executing Insurance Provisions - Domestic

GEPS-RISK-RISK009-CS Performance Guarantees

GEPS-SALES-SALES001-CS ITO Process

GEPS-SALES-SALES002-CS Maintenance Considerations for CSAs

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Non-Gas Turbine

Technical Courses

GEAERO-PROD-TECH-105 FAM LM2500 GT


GEE-ENG-TECH095-CS Triplogs

GEE-ENG-TECH096-CS Turbine Trips

GEE-PROD-TECH-164 Shaft Sealing System

GEE-PROD-TECH-177 Generator Assembly and Disassembly

GEE-PROD-TECH-179 Generator Design and Construction

GEE-PROD-TECH-180 Gas Turbine Fundamentals (7F)

GEE-PROD-TECH-181 Stator Winding Cooling System

GEPS-ENG-TECH001-CS PATAT 15 - Winterization

GEPS-ENG-TECH002-CS PATAT 6 - Lean Blowout

GEPS-ENG-TECH003-CS PATAT 13 - Compressor Bleed Valve System

GEPS-ENG-TECH004-CS PATAT 14 - Steam Turbine Startup and Shutdown Procedures

GEPS-ENG-TECH005-CS PATAT 8 - Drum Level 1: Introduction

GEPS-ENG-TECH006-CS PATAT 9 - Drum Level 2: Control Systems

GEPS-ENG-TECH007-CS PATAT 16 - Troubleshooting Liquid Fuel System Problems

GEPS-ENG-TECH008-CS PATAT 3 - GT Exhaust Gas Thermocouple Installation

GEPS-ENG-TECH009-CS PATAT 4 - Generator Brush Inspection & Maintenance

GEPS-ENG-TECH019-CS PATAT 10 - Drum Level 3: Condensate and Feedwater Pump Systems

GEPS-ENG-TECH020-CS PATAT 11 - Drum Level 4: Bypass Systems Course

GEPS-ENG-TECH038-CS PATAT 1- PATAT Indoctrination for GE Energy Employees and Customers

GEPS-ENG-TECH052-CS PATAT 7 - HRSG Operation and Maintenance

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Non-Gas Turbine

Technical Courses

GEPS-ENG-TECH054-CS PATAT 5 - High Exhaust Temperature Spread

GEPS-ENG-TECH055-CS PATAT 12 - Bearing Lube Oil & Hydraulics

GEPS-ENG-TECH061-CS PATAT 17 - Troubleshooting Gaseous Fuel System Problems

GEPS-ENG-TECH063-CS PATAT 2 - Plant Trip Reduction

GEPS-PROD-TECH-100 Generator Fundamentals

GEPS-PROD-TECH-101 Steam Turbine Fundamentals

GEPS-PROD-TECH-103 7FA Combustion Inspection

GEPS-PROD-TECH-105 Lube Oil Systems

GEPS-PROD-TECH-106 Hydraulic Oil, Trip Oil, and VIGV Systems

GEPS-PROD-TECH-108 Cooling and Sealing Air System

GEPS-PROD-TECH-109 Compressor Water Wash

GEPS-PROD-TECH112 Fuel and Atomizing Air Systems

GEPS-PROD-TECH-113 Steam and Water Injection

GEPS-PROD-TECH-114 Cooling Water

GEPS-PROD-TECH-120 Basics of Gas Turbine Combustion

GEPS-PROD-TECH-148 Vibration Fundamentals

GEPS-PROD-TECH-159 Generator Theory

GEPS-PROD-TECH-161 Generator Excitation

GEPS-PROD-TECH-163 Hydrogen Gas Control System

GEPS-RISK-RISK001-CSGER-3620: Heavy-Duty Gas Turbine Operating and Maintenance Considerations - Technical

Leadership Courses

GEE-PSKL-FLL-PGS Front Line Leadership Skills

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Attachment 2 – Plant Manager Qualification Cards

GE Energy

PGS Training & Development

Global Operation & Maintenance Services

Plant Manager Qualification Cards and Standards

Dated: 04/01/2012

Revision 0

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IntroductionPlant Manager Training Guidelines and Qualification2


IntroductionAs part of the Qualification program, every new candidate is required to undergo “On the Job Training” (OJT). During this program, candidates will be assigned a mentor at a given site. Also, new candidates are expected to satisfactorily complete all assigned on-line training courses and gather practical knowledge on the tasks that they would be performing as certified PMs.

This document lists the roles, responsibilities and tasks related to On-the-job training. It also lists the processes and standards to successfully complete the training program in the “Roles and Responsibilities” section, “OJT Tasks Handouts” and the “Processes and Standards” sections of the document.

Version History

Date and Version of Release Description

Date: Release: 1.0 First Release of the Qualification Card and Standards document.

Roles and Responsibilities

Roles Responsibilities

O&M Training Manager• Maintain this document, procedures, and guidelines

• Ensure secure storage of all completed OJT checklists

Mentor

• Teach and evaluate the new candidate.

• Ensure successful completion of all identified tasks for OJT

• Sign off the OJT handout upon successful completion of the tasks listed

• Guide the candidate during training and resolve practical issues

Region Manager (of the PM candidate)

• All mentor responsibilities list above if a mentor is not assigned

• Resolve any ambiguities and provide clarifications related to this document as may be needed

Candidate • Complete the tasks listed in the OJT Handout

Processes and StandardsAs part of the qualification process, a candidate is assigned a site and mentor by the Region Leadership. The candidate is required to satisfactorily complete the “On the Job Training” checklist within 24 months as established by the overall qualification program. Under special circumstances a candidate may be assigned to a site without a mentor. In such an event, the Region Manager owning the portfolio of the site automatically becomes the mentor.

A mentor is someone who both trains and evaluates the ability of a candidate to perform a task unsupervised. Mentoring is open-ended one-on-one training. The mentor trains the candidate as the mentor sees fit. When the mentor has determined the candidate

has adequate skills and knowledge associated with the task, the mentor then initials next to the task.

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Processes and StandardsPlant Manager Training Guidelines and Qualification2


Each OJT task has a corresponding evaluation level that determines what the candidate must do before the mentor initials the task as complete. These levels are Discuss, Simulate and Perform:

• Discuss: The mentor trains while simultaneously evaluating the candidate on the task exclusively through discussion.

• Simulate: The mentor trains the candidate on the task. The candidate is required to simulate executing the task while describing the expected result.

• Perform: The mentor trains the candidate on the task. The candidate then performs the actual task under the observation and supervision of the mentor.

In all cases, the mentor determines when the candidate is competent to perform the task alone. If the task is not applicable at the candidate’s site, the mentor strikes out the level and write in “N/A”.

Note: All Simulate or Perform levels include Discuss by default.

If it is not possible or practical to simulate or perform a task as required, the mentor should strike through the Level and indicate that this task was discussed. If the task is discussed via phone or web conference, the candidate can initial for the mentor.

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OJT Tasks Handout

Task Description Level MentorInitials/Date

Contract Financials

1. Explain the revenue recognition principles for O&M contract. Discuss _________/_________

2. Conduct a Margin Review using ICAM (If applicable) Discuss _________/_________

3. Validate contract model using ICAM (If applicable) Discuss _________/_________

4. Analyze the Catalog reports (If applicable) Discuss _________/_________

5. Analyze the Comparison reports (If applicable) Discuss _________/_________

6. Analyze the Count reports (If applicable) Discuss _________/_________

7. Analyze the Forecast reports (If applicable) Discuss _________/_________

8. Prepare S2 for site. Discuss _________/_________

9. Assess contract performance & profitability. Discuss _________/_________

Contract Management

10. Assess plant operation and CM&Us opportunities to determine extra-work opportunities. Discuss _________/_________

11. Support Sales, Comm Ops and engineering in developing GE offerings for repair, parts, and services Extra Work. Discuss _________/_________

Contract Operations

12. Locate project documents using ProjectNet (Customer Collaboration). Discuss _________/_________

13. Generate the purchase orders for parts and services required using the Demand Placement process. Discuss _________/_________

14. Coordinate with the third-party vendor in purchasing consumables. Discuss _________/_________

15. Obtain a current copy of your contract from CONSTOR Perform _________/_________

16. Obtain the certificates of insurance from GE and provide it to the customer. Discuss _________/_________

17. Obtain the certificate of insurance from the customer and provide it to GE.

18. Search for an approved external vendor. Perform _________/_________

19. Approve/reject charges against a contract. Perform _________/_________

20. Calculate contract escalation, if applicable. Perform _________/_________

21. Calculate discounts, if applicable. Perform _________/_________

22. Calculate taxes, if applicable. Perform _________/_________

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Contract Financials

23. Create a customer invoice. Perform _________/_________

24. Explain the payment procedures followed by the customer for your O&M contract. Discuss _________/_________

25. Define the roles and responsibilities of each player in the outage planning process. Discuss _________/_________

26. Explain the contractual requirements for O&M outages Discuss _________/_________

27. List the milestones in the Outage planning process. Discuss _________/_________

28. Follow QWI to execute a Forced Outage Discuss _________/_________

Complete ORAP DOE/FERC/NERC regulatory reports as applicable. Perform _________/_________

GE Internal Processes

29. Explain the significance of Policy 6.0 Discuss _________/_________

30. Explain the significance of Policy 5.0. Discuss _________/_________

31. Describe the scope, authority, and level of confidentiality of a DCI. (Design Change Instruction) Discuss _________/_________

32. Describe the scope, authority, and level of confidentiality of an ECN. (Engineering Change Notification) Discuss _________/_________

33. Describe the scope, authority, and level of confidentiality of a PMI. (Field Modification Instructions) Discuss _________/_________

34. Describe the scope, authority, and level of confidentiality of a GEH. (GE, External Complete Instructions) Discuss _________/_________

35. Describe the scope, authority, and level of confidentiality of a GEI. (GE, External Instructions) Discuss _________/_________

36. Describe the scope, authority, and level of confidentiality of a GEK. (GE, Instructions for Limited Distribution, complete data on special or non-special equipment.)

Discuss _________/_________

37. Describe the scope, authority, and level of confidentiality of a GER. (GE, Reprint) Discuss _________/_________

38. Describe the scope, authority, and level of confidentiality of a TIL. (Technical Information Letter) Discuss _________/_________

39. Describe the scope, authority, and level of confidentiality of a TIM. (Technical Information Memo) Discuss _________/_________

40. Describe the scope, authority, and level of confidentiality of a Hot List Item. Discuss _________/_________

41. Describe the scope, authority, and level of confidentiality of the Top Issues List. Discuss _________/_________

42. Describe the scope, authority, and level of confidentiality of a Fact Sheet. Discuss _________/_________

43. Coordinate with the Routing Center any shipments to your site (pick-ticket, BOL, packing list, shipping list, CRM, AWB, HAWB, Incoterms, Parts ERP, POST) Discuss _________/_________

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Contract Financials

44. Create an opening letter to initiate P&RS services. Discuss _________/_________

General

45. Retrieve documents from PLM Discuss _________/_________

46. Use eField Services as needed by your contract. Discuss _________/_________

47. Use ePS (Product Services Portal) as needed by your contract. Discuss _________/_________

48. Use eRFQ (Request For Quote) as needed by your contract. Discuss _________/_________

49. Use eWarranty as needed by your contract. Discuss _________/_________

50. Use GE PartsEdge as needed by your contract. Discuss _________/_________

51. Use PowerSmarts as needed by your contract. Discuss _________/_________

52. Use Product Service Web Page as needed by your contract. Discuss _________/_________

53. Use PAC/Clarify to raise/resolve issues. Discuss _________/_________

Law & Regulations

54. Control GE "Proprietary" information in your possession. Discuss _________/_________

55. Explain the circumstances that might require GE Legal assistance. Discuss _________/_________

56. Explain the legal issues surrounding regulatory reporting. Discuss _________/_________

57. State the criteria under which documentation is designated as "Proprietary". Discuss _________/_________

58. Apply governmental laws and regulations for facility operation (e.g. environmental discharges, wildlife, labor law/relations, OSHA, EU directives, etc). Discuss _________/_________

Plant Maintenance

59. Request a CM&U using the Demand Placement process. Perform _________/_________

60. Execute plant maintenance based on the concepts of corrective, preventative, predictive and reliability based maintenance Discuss _________/_________

61. Explain parameters to be monitored/recorded while unit is running (GER-3620) Discuss _________/_________

Plant Operations

62. Determine the cost of a trip and/or equipment failure at your plant under various conditions. Perform _________/_________

Stakeholder Relations

63. Resolve customer disputes. Discuss _________/_________

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Plant Manager Training Guidelines and Qualification References


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Contract Financials

64. Explain the legal risk associated with communication & documentation related to O&M contracts. Discuss _________/_________

65. Analyze NPS survey results and create an action plan. Discuss _________/_________

66. Create CIR (Customer Issue Resolution Module). Discuss _________/_________

Technical Knowledge

67. Understand purpose & function of OSM (On Site Monitoring). Discuss _________/_________

68. Understand purpose & function of OSM (On Site Monitoring). Discuss _________/_________

69. Understand factors that impact Plant Performance / Heat Rate. Discuss _________/_________

70. Use EMAP (plant optimization software) to optimize plant performance. Discuss _________/_________

71. Identify and share site best practices and corrective actions with the fleet. Discuss _________/_________

72. Perform RCA and corrective actions and understand relationship to plant & fleet reliability Discuss _________/_________

____________________________ __________________ _______________PM Signature SSO Date

____________________________ __________________ _______________Mentor Signature SSO Date

When complete, mail a copy of (or scan and e-mail) this checklist to [email protected] to be recorded in myLearning.

Queries and More InformationThis document lays out the process for participating in On the Job training. If there are queries about a specific task, the candidate should e-mail the queries to:

[email protected]

3 Maintenance M

anager

3 MaintenanceManagerTrainingGuidelinesandQualification

1.0 Purpose and Scope

2.0 Definitions

3.0 Roles and Responsibilities3.1 O&M Training Manager3.2 Region Manager3.3 Plant Manager3.4 Mentors3.5 Maintenance Manager Candidate

4.0 Policy

5.0. Training Process5.1 Planning and Design5.2 Curriculum Development5.3 Major Training Categories5.4 Execution5.5 Training Exemption Requests5.6 Continuing Training5.7 Training Review

6.0 Management Review Requirement Summary

7.0 References7.1 Introduction7.2 Version History7.3 Roles and Responsibilities7.4 Processes and Standards7.5 Queries and More Information

Attachment 1 – Maintenance Manager Curricula

Attachment 2 – Maintenance Manager Qualification Cards

Purpose and Scope

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Maintenance Manager Training Guidelines and Qualification


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1.0 Purpose and ScopeMaintenance Managers provide key value for the Global Operations and Maintenance Services business and its customers. Their technical knowledge, leadership and business acumen are fundamental to the success and profitability of GO&MS contracts around the world.

The purpose of this Work Instruction is to establish and maintain this standard of excellence through Maintenance Manager (MM) training and qualification. The work instruction ensures MMs attain and maintain the knowledge, skills, and abilities required to perform their roles and responsibilities in an effective manner.

This training program applies to all Maintenance Managers at any GE O&M plant.












PM Plant Manager










3.2 Region ManagerThe role of the Region Manager is to evaluate and identify training and developmental needs for all MMs in their region. It is their responsibility is to:


• Designate certified PMs under their direction to serve as mentors for qualification candidates as needed.

PolicyMaintenance Manager Training Guidelines and Qualification

3-2 GE Energy | O&M Training Playbook (06/2012)

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• Monitor execution of training plan, support the development process, and ensure completion of the training curriculum.


3.3 Plant ManagerThe role of the Plant Manager is to monitor execution of the training plan, support participation in the development process, and ensure MMs complete the training curriculum.

3.4 MentorsMentors are MMs appointed at the discretion of their respective Region Manager to assist with on-the-job training of MM qualification candidates. Their responsibilities may include:


• Creating training material for the MM training program when assigned to do so by their Manager.

3.5 Maintenance Manager CandidateMMs seeking qualification must satisfactorily complete all phases of the Training Program as specified in this document within 24 months of being assigned to the curriculum.


MMs newly assigned to their position must complete their initial training and qualification process within 24 months of being assigned to the curriculum. After completing initial qualification, candidates must complete all newly assigned training within the prescribed time to maintain their qualified status. This is referred to as Continuing Training.

Maintenance Managers who do not satisfactorily complete their initial training and qualification per requirement guidelines, and who do not annually maintain their certified status as described in this document will be evaluated commensurate with their annual performance goals and objectives.

5.0 Training ProcessMaintenance Managers work in a highly technical environment and manage personnel with various technical backgrounds. They are also responsible for the implementation and upgrades of their site Computerized Maintenance Management System (CMMS) including its utilization by all plant personnel. As maintenance leaders, they drive the Reliability Based Maintenance philosophy which seeks to improve plant and equipment availability and reliability at the lowest possible cost. Finally, MMs frequently interact with the site customer, which requires MMs to be proficient at listening and understanding customers’ needs.

The MM training program must address the breadth of these responsibilities.

5.1 Planning and DesignTable 1 indicates the terminal training objectives with respect to the MMs main role and responsibilities.

Training Process

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Table - 1


Contract Management Understand the scope and content of their O&M contract such that they can equitably fulfill contract requirements.

Contract Operations Participate in contract activities and functions such as outage planning, customer reporting and customer and personnel meetings so that contract requirements are fulfilled.

Stakeholder Relations Manage customer and labor relations. Improve personnel performance by effectively leading and training them to improve their overall skills and technical knowledge.


Law & RegulationsUnderstand scope and requirements of legal regulations defined by entities such as DOE, FERC, NERC, OSHA, etc. and how these regulations impact plant maintenance activities. Drive the fulfillment of all these requirements.

Plant MaintenanceUnderstand and lead plant maintenance activities to improve plant overall reliability and availability. Ensure appropriate usage of CMMS among all plant personnel. Lead and support implementation of Reliability Based Maintenance (RBM).

Project ManagementManage the execution of all plant upgrades and system improvements. Understand and apply all the tools and methods for effective project management so that these upgrades are performed on-time and under budget.

Technical Knowledge Understand the design basis and basic functionalities of all plant equipment & systems. Drive plant operational efficiency, Evaluate the impact and feasibility of new power plant technologies.

The training program and courses are derived from task categories described in Table 1. These task categories are reviewed every three years as a minimum to keep the training program up-to-date with MM changing roles and responsibilities.

These major responsibility categories are grouped into four training areas: Technical, Business Acumen, Leadership and On-the-Job Training as described in Curriculum Development.

Training ProcessMaintenance Manager Training Guidelines and Qualification


3

5.2 Curriculum DevelopmentFour curriculum tracks have been established to improve training efficiency. These tracks are based on the different plant technologies that MMs manage for the GO&MS business. The track approach to the curricula lets MMs focus their training effort on the concepts and content most applicable to their sites. The four curriculum tracks are:

• O&M MM Qualification – Heavy Duty Gas Turbine Combined Cycle.

• O&M MM Qualification – Heavy Duty Gas Turbine Simple Cycle

• O&M MM Qualification - Aero Gas Turbine

• O&M MM Qualification - Non-Gas Turbine Power Plant

MMs that transfer to a new site with different technologies will be assigned the appropriate curriculum. Once the new training is assigned, the MM must complete it within 12 months.




• Business AcumenThis non-technical training describes all internal GE processes, systems and tools MMs use to perform major contract tasks. These include but are not limited to warranty management, contract management, customer management, and sales and service business processes. It also includes contract margin review, sourcing and billing processes, etc. For the latest list of Business Acumen courses, see Attachment #1.

• Leadership TrainingMMs need very strong communication, team performance and technology-driven leadership skills to succeed in an environment with constant interaction between man and sophisticated machinery and where customers are vigilant of all aspects of contract fulfillment and delivery. Leadership training enables MMs to support key business initiatives, keep pace with changing business requirements and model GE values. It also enables MMs to manage customer relations, labor relations and personnel performance at their sites. For the latest list of Leadership Training courses, see Attachment #1.

• On the Job Training (OJT)This covers aspects of the training that are most effectively delivered via one-on-one interaction with a mentor. This training is structured as a list of MM tasks and activities that, due to their scope and content, do not require classroom or computer-based sessions. OJT includes a variety of tasks from technical to business processes.

Mentors ensure all OJT tasks are completed successfully by the MM candidate. Mentors are responsible for guiding MMs through the OJT list and signing off on all items as MMs successfully complete them. For the latest revision of PM OJT checklist, see Attachment #2.

5.4 Execution Candidates must successfully complete all modules of the training program to achieve qualification. Candidates must complete all of the above phases either by direct participation and approval, or by demonstrating competency in one or more areas and being granted exemption. See Training Exemption Requests. Note: Due to varying schedules and business needs, candidates may need to adjust the sequence of their training.

5.5 Training Exemption RequestsWhen a candidate possesses the knowledge and skills associated with any given training course or item, the candidate may be exempted from that area of training. The candidate must present objective evidence showing they possess the knowledge and skill. Objective Evidence may be presented in the form of training certificates, diplomas, myLearning records and other items. Resumes alone do NOT qualify as objective evidence.

Training Exemption Requests for selected items of the Qualification Program are submitted by the candidate and approved by the appropriate Region Manager and O&M Training Manager based on the objective evidence.

Management Review Requirement Summary

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The Training Exemption request work flow (WF) process can be started from the PGS Training Community Support Central site under “Process” at:

http://supportcentral.ge.com/products/sup_products.asp?prod_id=10832

5.6 Continuing TrainingContinuing training topics are identified and added to the training curriculum as needed. All individuals assigned to the curriculum must successfully complete this new assigned training in order to be certified.

5.7 Training ReviewAn O&M Training Review Board (TRB) evaluates training curriculum effectiveness.

Annually, at a minimum, the O&M Training Manager will chair a meeting with the GE Global O&M General Manager or designee, a Region Manager, and an incumbent MM. This review board will identify enhancements and modifications to the PM training curriculum such as:

• Program effectiveness

• Training content

• Continuing training topics

6.0 Management Review Requirement SummaryThe following management reviews must be conducted and documented.

[Table QAP 001-01] Management Review Requirement Summary

Frequency Responsibility Item Notes

Annual PGS Quality Program Manager, Manager O&M TrainingReview this instruction for applicability.

Annual O&M Operations Leader Participate in Training Review Meeting

Annual O&M Training Manager Conduct Training Review Meeting

7.0 References• GEEQMS 6.2.2, Competence, Awareness and Training

• O&M Quality Assurance Procedure 007 Staffing &Training

ReferencesMaintenance Manager Training Guidelines and Qualification


3

Maintenance Manager Curricula

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Maintenance Manager Training Guidelines and Qualification3


Attachment 1 – Maintenance Manager Curricula

Maintenance Manager CurriculaMaintenance Manager Training Guidelines and Qualification

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3


Maintenance Manager Training Curricula Training Courses:


Non-Gas Turbine

Non-Technical Courses

GEE-ENG-TECH099-CS Outage Excellence

GEE-FIN-FIN005-CS Contractual Services Enterprise Resource Planning (CS ERP) Finance

GEE-IT-IM037-CS eWarranty

GEE-IT-IM041-CS ICAM for Users

GEE-QUAL-RCA-e GEE eRCA COURSE (Web, Pre-requisite)

GEPS-ENG-TECH013-CS Forced Outage

GEPS-ENG-TECH014-CS Red Flag Review

GEPS-FIN-FIN001-CS CS Financial Overview

GEPS-FIN-FIN012-CS Contract Payment Stream and Escalation

GEPS-FIN-FIN020-CS Margin Review

GEPS-FIN-FIN030-CS Invoicing and Billing Responsibilities of a Contract Performance Manager (CPM)

GEPS-HR-HR0010-CS Contract Performance Manager and Plant Manager Duties

GEPS-HR-HR001-CS Introduction To Contractual Services

GEPS-LEGAL-LEGAL001-CS Contractual Service Agreements

GEPS-LEGAL-LEGAL003-CS Insurance Considerations for Contracts

GEPS-LEGAL-LEGAL005-CS Contract Performance and Usage

GEPS-LEGAL-LEGAL007-CS Executing Insurance Provisions - Global

GEPS-LEGAL-LEGAL008-CS Executing Insurance Provisions - Domestic

GEPS-RISK-RISK009-CS Performance Guarantees

GEPS-SALES-SALES001-CS ITO Process

GEPS-SALES-SALES002-CS Maintenance Considerations for CSAs


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Non-Gas Turbine

Technical Courses



GEE-ENG-TECH095-CS Triplogs

GEE-ENG-TECH096-CS Turbine Trips

GEE-PROD-TECH-164 Shaft Sealing System

GEE-PROD-TECH-177 Generator Assembly and Disassembly

GEE-PROD-TECH-179 Generator Design and Construction

GEE-PROD-TECH-180 Gas Turbine Fundamentals (7F)

GEE-PROD-TECH-181 Stator Winding Cooling System

GEPS-ENG-TECH001-CS PATAT 15 - Winterization

GEPS-ENG-TECH002-CS PATAT 6 - Lean Blowout

GEPS-ENG-TECH003-CS PATAT 13 - Compressor Bleed Valve System

GEPS-ENG-TECH004-CS PATAT 14 - Steam Turbine Startup and Shutdown Procedures

GEPS-ENG-TECH005-CS PATAT 8 - Drum Level 1: Introduction

GEPS-ENG-TECH006-CS PATAT 9 - Drum Level 2: Control Systems

GEPS-ENG-TECH007-CS PATAT 16 - Troubleshooting Liquid Fuel System Problems

GEPS-ENG-TECH008-CS PATAT 3 - GT Exhaust Gas Thermocouple Installation

GEPS-ENG-TECH009-CS PATAT 4 - Generator Brush Inspection & Maintenance

GEPS-ENG-TECH019-CS PATAT 10 - Drum Level 3: Condensate and Feedwater Pump Systems

GEPS-ENG-TECH020-CS PATAT 11 - Drum Level 4: Bypass Systems Course

GEPS-ENG-TECH038-CS PATAT 1- PATAT Indoctrination for GE Energy Employees and Customers

GEPS-ENG-TECH052-CS PATAT 7 - HRSG Operation and Maintenance

GEPS-ENG-TECH054-CS PATAT 5 - High Exhaust Temperature Spread

GEPS-ENG-TECH055-CS PATAT 12 - Bearing Lube Oil & Hydraulics


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Non-Gas Turbine

GEPS-ENG-TECH061-CS PATAT 17 - Troubleshooting Gaseous Fuel System Problems

GEPS-ENG-TECH063-CS PATAT 2 - Plant Trip Reduction

GEPS-PROD-TECH-100 Generator Fundamentals

GEPS-PROD-TECH-101 Steam Turbine Fundamentals

GEPS-PROD-TECH-103 7FA Combustion Inspection

GEPS-PROD-TECH-105 Lube Oil Systems

GEPS-PROD-TECH-106 Hydraulic Oil, Trip Oil, and VIGV Systems

GEPS-PROD-TECH-108 Cooling and Sealing Air System

GEPS-PROD-TECH-109 Compressor Water Wash

GEPS-PROD-TECH112 Fuel and Atomizing Air Systems

GEPS-PROD-TECH-113 Steam and Water Injection

GEPS-PROD-TECH-114 Cooling Water

GEPS-PROD-TECH-120 Basics of Gas Turbine Combustion

GEPS-PROD-TECH-148 Vibration Fundamentals

GEPS-PROD-TECH-159 Generator Theory

GEPS-PROD-TECH-161 Generator Excitation

GEPS-PROD-TECH-163 Hydrogen Gas Control System

GEPS-RISK-RISK001-CSGER-3620: Heavy-Duty Gas Turbine Operating and Maintenance Considerations - Technical

Leadership Courses

GEE-PGS-OPS-TECH-001 Reliability Based Maintenance Implementation

Maintenance Manager Qualification Cards

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Attachment 2 – Maintenance Manager Qualification Cards

GE Energy

PGS Training & Development

Global Operation & Maintenance Services

Maintenance Manager Qualification Cards and Standards

Dated: 04/01/2012

Revision 0

Maintenance Manager Qualification CardsMaintenance Manager Training Guidelines and Qualification

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IntroductionAs part of the Qualification program, every new Maintenance Manager candidate is required to undergo “On the Job Training” (OJT). During this program, candidates will be assigned a mentor at a given site. Also, new candidates are expected to satisfactorily complete all assigned on-line training courses and gather practical knowledge on the tasks that they would be performing as certified MMs.

This document lists the roles, responsibilities and tasks related to On-the-job training. It also lists the processes and standards to successfully complete the training program in the “Roles and Responsibilities” section, “OJT Tasks Handouts” and the “Processes and Standards” sections of the document.

Version History

Date and Version of Release Description

Date: Release: 1.0 First Release of the Qualification Card and Standards document.

Roles and Responsibilities

Roles Responsibilities

O&M Training Manager• Maintain this document, procedures, and guidelines

• Ensure secure storage of all completed OJT checklists

Mentor

• Teach and evaluate the new candidate.

• Ensure successful completion of all identified tasks for OJT

• Sign off the OJT handout upon successful completion of the tasks listed

• Guide the candidate during training and resolve practical issues

Region Manager (of the MM candidate)• All mentor responsibilities list above if a mentor is not assigned

• Resolve any ambiguities and provide clarifications related to this document as may be needed

Candidate • Complete the tasks listed in the OJT Handout

Processes and StandardsAs part of the qualification process, a candidate is assigned a site and mentor by the Region Leadership. The candidate is required to satisfactorily complete the “On the Job Training” checklist within 24 months as established by the overall qualification program. Under special circumstances a candidate may be assigned to a site without a mentor. In such an event, the Region Manager owning the portfolio of the site automatically becomes the mentor.

A mentor is someone who both trains and evaluates the ability of a candidate to perform a task unsupervised. Mentoring is open-ended one-on-one training. The mentor trains the candidate as the mentor sees fit. When the mentor has determined the candidate has adequate skills and knowledge associated with the task, the mentor then initials next to the task.

Each OJT task has a corresponding evaluation level that determines what the candidate must do before the mentor initials the task as complete. These levels are Discuss, Simulate and Perform:

• Discuss: The mentor trains while simultaneously evaluating the candidate on the task exclusively through discussion.

• Simulate: The mentor trains the candidate on the task. The candidate is required to simulate executing the task while describing the expected result.

• Perform: The mentor trains the candidate on the task. The candidate then performs the actual task under the observation and supervision of the mentor.


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In all cases, the mentor determines when the candidate is competent to perform the task alone. If the task is not applicable at the candidate’s site, the mentor strikes out the level and write in “N/A”.

Note : All Simulate or Perform levels include Discuss by default.

If it is not possible or practical to simulate or perform a task as required, the mentor should strike through the Level and indicate that

this task was discussed. If the task is discussed via phone or web conference, the candidate can initial for the mentor.

OJT Tasks Handout


Contract Operations

1 Locate project documents using Customer Collaboration (i.e. ProjectNet) Discuss _________/_________

2 Generate the purchase orders for parts and services required using the Demand Placement process. Discuss _________/_________

3 Coordinate with the third-party vendor in purchasing consumables. Discuss _________/_________

4 Obtain a current copy of your contract from CONSTOR Perform _________/_________

5 Search for an approved external vendor. Perform _________/_________

6 Define the roles and responsibilities of each player in the outage planning process. Discuss _________/_________

7 Explain the contractual requirements for O&M outages Discuss _________/_________

8 List the milestones in the Outage planning process. Discuss _________/_________

9 Follow QWI to execute a Forced Outage Discuss _________/_________

10 Complete ORAP DOE/FERC/NERC regulatory reports as applicable. Perform _________/_________

GE Internal Processes

11 Explain the significance of Policy 6.0 Discuss _________/_________

12 Explain the significance of Policy 5.0. Discuss _________/_________

13 Describe the scope, authority, and level of confidentiality of a DCI. (Design Change Instruction) Discuss _________/_________

14 Describe the scope, authority, and level of confidentiality of an ECN. (Engineering Change Notification) Discuss _________/_________

15 Describe the scope, authority, and level of confidentiality of a FMI. (Field Modification Instructions) Discuss _________/_________

16 Describe the scope, authority, and level of confidentiality of a GEH. (GE, External Complete Instructions) Discuss _________/_________

17 Describe the scope, authority, and level of confidentiality of a GEI. (GE, External Instructions) Discuss _________/_________

18Describe the scope, authority, and level of confidentiality of a GEK. (GE, Instructions for Limited Distribution, complete data on special or non-special equipment.)

Discuss _________/_________

19 Describe the scope, authority, and level of confidentiality of a GER. (GE, Reprint) Discuss _________/_________


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20 Describe the scope, authority, and level of confidentiality of a TIL. (Technical Information Letter) Discuss _________/_________

21 Describe the scope, authority, and level of confidentiality of a TIM. (Technical Information Memo) Discuss _________/_________

22 Describe the scope, authority, and level of confidentiality of a Hot List Item. Discuss _________/_________

23 Describe the scope, authority, and level of confidentiality of the Top Issues List. Discuss _________/_________

24 Describe the scope, authority, and level of confidentiality of a Fact Sheet. Discuss _________/_________

25 Coordinate with the Routing Center any shipments to your site (pick-ticket, BOL, packing list, shipping list, CRM, AWB, HAWB, Incoterms, Parts ERP, POST) Discuss _________/_________

26 Create an opening letter to initiate P&RS services. Discuss _________/_________

General

27 Retrieve documents from PLM Discuss _________/_________

28 Use eField Services as needed by your contract. Discuss _________/_________

29 Use ePS (Product Services Portal) as needed by your contract. Discuss _________/_________

30 Use eRFQ (Request For Quote) as needed by your contract. Discuss _________/_________

31 Use GE PartsEdge as needed by your contract. Discuss _________/_________

32 Use PowerSmarts as needed by your contract. Discuss _________/_________

33 Use Product Service Web Page as needed by your contract. Discuss _________/_________

34 Use PAC/Clarify to raise/resolve issues. Discuss _________/_________

Law & Regulations

35 Control GE "Proprietary" information in your possession. Discuss _________/_________

36 Explain the circumstances that might require GE Legal assistance. Discuss _________/_________

37 Explain the legal issues surrounding regulatory reporting. Discuss _________/_________

38 State the criteria under which documentation is designated as "Proprietary". Discuss _________/_________

39Apply governmental laws and regulations for facility operation (e.g. environmental discharges, wildlife, labor law/relations, OSHA, EU directives, etc.).

Discuss _________/_________

40 Identify the regulations related to fire protection equipment and training at your facility. Discuss _________/_________

41 Demonstrate a general understanding of the requirements of the boiler and pressure vessel code applicable to your facility (e.g., ASME Code) Discuss _________/_________

Plant Maintenance

42 Request a CM&U using the Demand Placement process. Perform _________/_________


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43 Execute plant maintenance based on the concepts of corrective, preventative, predictive and reliability based maintenance Discuss _________/_________

44 Explain parameters to be monitored/recorded while unit is running (GER-3620) Discuss _________/_________

Within the Maintenance Playbook, demonstrate an understanding of how the following modules/topics/issues should be addressed at a GE O&M facility:

45 Management Engagement - Establish Common O&M Maintenance Philosophy Discuss _________/_________

46 Management Engagement - Launch and Facilitate O&M Review Board Discuss _________/_________

47 Management Engagement - Establish Site RBM Teams Discuss _________/_________

48 Management Engagement - Quality Assurance Procedure – QAP Discuss _________/_________

49 Management Engagement - CMMS Maintenance and Performance Reporting Discuss _________/_________

50 Management Engagement - Communication Documentation Discuss _________/_________

51 Management Engagement - Drive CMMS Utilization Discuss _________/_________

52 Management Engagement - Project Pacing Discuss _________/_________

53 Management Engagement - Global or Region RBM Meetings Discuss _________/_________

54 Data Standardization - Workflow Discuss _________/_________

55 Data Standardization - Work Order Type Discuss _________/_________

56 Data Standardization - Work Order Status Discuss _________/_________

57 Data Standardization - Work Order Priorities Discuss _________/_________

58 Data Standardization - Work Order Scheduling Discuss _________/_________

59 Data Standardization - Mapping Discuss _________/_________

60 Data Standardization - Cost Tracking Discuss _________/_________

61 Data Standardization - Asset Class-Type Standardization Discuss _________/_________

62 Data Standardization - Nameplate Data Standardization for RBM Reporting Discuss _________/_________

63 Maintenance Standardization - PM-PdM-CM Maintenance Ratios Discuss _________/_________

64 Maintenance Standardization - Maintenance Survey and Analysis Discuss _________/_________

65 Maintenance Standardization - Maintenance Guidelines Discuss _________/_________

66 Maintenance Standardization - Maintenance Guidelines Preamble Discuss _________/_________

67 Maintenance Standardization - Published Guidelines Discuss _________/_________

68 Maintenance Optimization - FMEA Critical Equipment Identification Discuss _________/_________


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69 Maintenance Optimization - Critical Asset Maintenance PM-PdM Enhancement Discuss _________/_________

70 Maintenance Optimization - Low Risk Asset PM-PdM Elimination Discuss _________/_________

71 Maintenance Optimization - Run to Failure Discuss _________/_________

72 Maintenance Optimization - Continuous Improvement Cycle Discuss _________/_________

73 Reliability Based Maintenance - Lessons Learned & Maintenance information Letters Discuss _________/_________

74 Reliability Based Maintenance - Failure Reporting Discuss _________/_________

75 Reliability Based Maintenance - Failure Code Updates Discuss _________/_________

76 Reliability Based Maintenance - Data Warehouse Discuss _________/_________

77 Reliability Based Maintenance - RBM Reporting and Analysis – Phase 1 Discuss _________/_________

78 Reliability Based Maintenance - RBM Reporting and Analysis – Phase 2 Discuss _________/_________

79 Reliability Based Maintenance - Optimize Maintenance Strategy Discuss _________/_________

80 Reliability Based Maintenance - Failure Code Discuss _________/_________

81 Conduct an acoustical examination of a piece of equipment. Discuss _________/_________

82 Conduct an infrared examination of a piece of electrical equipment. Discuss _________/_________

83 Describe the proper way to locate and approach a steam leak. Discuss _________/_________

84 Describe the proper lifting and rigging policy and procedures at the facility. Discuss _________/_________

Plant Operations

85 Explain the plant’s Personnel Communication Standard (e.g., 3-way, phonetic alphabet, etc.) Discuss _________/_________

86 Determine the cost of a trip and/or equipment failure at your plant under various conditions. Perform _________/_________

Stakeholder Relations

87 Explain the legal risk associated with communication & documentation related to O&M contracts. Discuss _________/_________

Technical Knowledge

88 Understand purpose & function of OSM (On Site Monitoring). Discuss _________/_________

89 Understand factors that impact Plant Performance / Heat Rate. Discuss _________/_________

90 Identify and share site best practices and corrective actions with the fleet. Discuss _________/_________

91 Perform RCA and corrective actions and understand relationship to plant & fleet reliability Discuss _________/_________


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CMMS Tasks

General System Knowledge Objectives

92 Describe the basic modules the CMMS. Discuss _________/_________

93 Demonstrate an ability to log-on to and navigate the CMMS. Discuss _________/_________

Code Tables Objectives - Demonstrate the ability to

94 Edit/Add codes in code tables. Discuss _________/_________

Equipment Objectives - Demonstrate the ability to

95 Edit/Add equipment to the equipment data table. Discuss _________/_________

96 Find an existing piece of equipment in the equipment data table. Discuss _________/_________

Inventory Objectives - Demonstrate the ability to

97 Edit/Add spare parts to the inventory data table. Discuss _________/_________

98 Find an existing spare part in the inventory data table. Discuss _________/_________

99 Link a spare part to a piece of equipment. Discuss _________/_________

100 Track spare parts and matching equipment. Discuss _________/_________

Maintenance Objectives - Demonstrate the ability to

101 Create a corrective work request/order in the work order table. Discuss _________/_________

102 Create multiple tasks associated with a work order. Discuss _________/_________

103 Estimate time and materials associated with a work order. Discuss _________/_________

104 Create a PM definition for a specific piece of equipment. Discuss _________/_________

105 Generate a PM work order from a PM definition for a specific piece of equipment and/or date range. Discuss _________/_________

106 Write a work order procedure for a specific PM definition. Discuss _________/_________

107 Generate a spare part pick-ticket associated with a work order. Discuss _________/_________

108 Issue spare parts to a pick-ticket. Discuss _________/_________

109 Return a part to inventory that was included on a pick-ticket. Discuss _________/_________

110 Close a work order. Discuss _________/_________

111 Complete a time card associated with a work order. Discuss _________/_________

112 Generate a maintenance schedule in the CMMS. Discuss _________/_________


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Personnel Objectives - Demonstrate the ability to

113 Create a new employee in the personnel data table. Discuss _________/_________

114 Assign personnel to a planned work order. Discuss _________/_________

115 Fill out a time card associated with the completion of a work order. Discuss _________/_________

Purchasing Objectives - Demonstrate the ability to

116 Complete a purchase requisition of a stock item. Discuss _________/_________

117 Complete a purchase requisition of a non-stock item. Discuss _________/_________

118 Create a purchase order. Discuss _________/_________

119 Approve and print a purchase order (authorized personnel only). Discuss _________/_________

120 Receive non-stock items on a purchase order. Discuss _________/_________

121 Print a put-away ticket for stock items received in a shipment. Discuss _________/_________

122 Patch the vendor invoice to a shipment of goods. Discuss _________/_________

Reports and Queries Objectives - Demonstrate the ability to

123 Search for a specific piece of equipment or spare part. Discuss _________/_________

124 Print a code table report. Discuss _________/_________

125 Use the filter screens to create a report limited to specified criterion. Discuss _________/_________

126 Export data from a CMMS data table to an available format. Discuss _________/_________

EHS Tasks

Discuss the plant plans and procedures related to the following events:

127 Transformer fire Discuss _________/_________

128 Lube/Seal Oil fire Discuss _________/_________

129 Hydrogen fire Discuss _________/_________

130 Fuel Oil fire (at storage tanks as well as at GT) Discuss _________/_________

131 Natural Gas fire Discuss _________/_________

132 Office building fire Discuss _________/_________

133 Fuel Oil Leak Discuss _________/_________

134 Lube Oil Leak Discuss _________/_________


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135 Chemical Spill Discuss _________/_________

136 Ammonia Release Discuss _________/_________

137 Malfeasance or Unlawful Acts Discuss _________/_________

138 Electrical module fire Discuss _________/_________

139 Identify the locations of Spill Kits. Perform _________/_________

140 Identify the locations of First Aid Kits. Perform _________/_________

Identify the storage locations and policies for the following:

141 Volatile chemicals Perform _________/_________

142 Gas cylinders (oxygen, acetylene, nitrogen, CO2) Perform _________/_________

143 Flammable liquids Perform _________/_________

State the plant procedures and policies for the following EHS related topics:

144 Temporary storage of flammable materials Discuss _________/_________

145 Transient flammable materials Discuss _________/_________

146 Fire door use Discuss _________/_________

147 Smoking and open flames Discuss _________/_________

148 Motor vehicle operation Discuss _________/_________

149 Use of fall protection Discuss _________/_________

150 Ladder use Discuss _________/_________

151 Scaffolding construction and use Discuss _________/_________

152 LockOut Tagout (LOTO) Discuss _________/_________

____________________________ __________________ _______________ PM Signature SSO Date

____________________________ __________________ _______________ Mentor Signature SSO Date

When complete, mail a copy of (or scan and e-mail) this checklist to [email protected] to be recorded in myLearning.


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Queries and More Information

This document lays out the process for participating in On the Job training. If there are queries about a specific task, candidate

should e-mail the queries to:

[email protected]

4 Operations M

anager

4 Operations Manager Training Guidelines and Qualification1.0 Purpose and Scope

2.0 Definitions

3.0 Roles and Responsibilities3.1 O&M Training Manager3.2 Region Manager3.3 Plant Manager3.4 Mentors3.5 Operations Manager Candidate

4.0 Policy

Training ProcessPlanning and DesignCurriculum DevelopmentMajor Training CategoriesExecution Training Exemption RequestsContinuing TrainingTraining ReviewManagement Review Requirement SummaryReferences

Attachment 1 – Operations Manager Curricula

Attachment 2 – Operations Manager Qualification Cards

4-1

Operations Manager Training Guidelines and Qualification Purpose and Scope4


1.0 Purpose and ScopeOperations Managers provide key value for the Global Operations and Maintenance Services business and its customers. Their technical knowledge, leadership and business acumen are fundamental to the success and profitability of GO&MS contracts around the world.

The purpose of this Work Instruction is to establish and maintain this standard of excellence through Operations Manager (OM) training and qualification. The work instruction ensures OMs attain and maintain the knowledge, skills, and abilities required to perform their roles and responsibilities in an effective manner.

This training program applies to all Operations Managers at any GE O&M plant.










OM Operations Manager



PM Plant Manager










Operations Manager Training Guidelines and Qualification

4-2

Policy4


3.2 Region ManagerThe role of the Region Manager is to evaluate and identify training and developmental needs for all OMs in their region. It is their responsibility is to:


• Designate certified OMs under their direction to serve as mentors for qualification candidates as needed.


• Monitor execution of training plan, support the development process, and ensure completion of the training curriculum.


3.3 Plant ManagerThe role of the Plant Manager is to monitor execution of training plan, support participation in the development process, and ensure OMs complete the training curriculum.

3.4 MentorsMentors are OMs appointed at the discretion of their respective Region Manager to assist with on-the-job training of OM qualification candidates. Their responsibilities may include:


• Creating training material for the OM training program when assigned to do so by their Manager.

3.5 Operations Manager CandidateOMs seeking qualification must satisfactorily complete all phases of the Training Program as specified in this document within 24 months of being assigned to the curriculum.


OMs newly assigned to their position must complete their initial training and qualification process within 24 months of being assigned to the curriculum. After completing initial qualification, candidates must complete all newly assigned training within the prescribed time to maintain their qualified status. This is referred to as Continuing Training.

Operations Managers who do not satisfactorily complete their initial training and qualification per requirement guidelines, and who do not annually maintain their qualified status as described in this document will be evaluated commensurate with their annual performance goals and objectives.

5.0 Training ProcessOperations Managers work in a highly technical environment and manage personnel with various technical backgrounds. They are responsible for the physical operation of the plant through the Control Room Operators and Outside Area Operators they supervise.

OMs share these responsibilities to different degrees with all plant personnel, engineers and technicians. It is the OM responsibility to lead this team of technicians to a high level of performance

The OM training program must address the breadth of these responsibilities.

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Operations Manager Training Guidelines and Qualification Training Process4


5.1 Planning and DesignTable 1 indicates the terminal training objectives with respect to the OMs main role and responsibilities.

Table - 1


Contract Management Understand the scope and content of the O&M contract such that they can equitably fulfill contract requirements within their scope of responsibility.

Contract Operations Participate in contract related activities such as outage planning, customer reporting and customer and personnel meetings so that contract requirements are fulfilled.

Stakeholder Relations Manage labor relations. Improve personnel performance by effectively leading and training them to improve their overall skills and technical knowledge.


Law & RegulationsUnderstand scope and requirements of legal regulations defined by entities such as DOE, FERC, NERC, OSHA, etc. and how these regulations impact plant operations. Drive the fulfillment of all these requirements.

Plant Operations Understand and lead plant operations activities to improve plant overall reliability and availability.

Project ManagementManage the execution of plant operational upgrades and system improvements. Understand and apply all the tools and methods for effective project management so that these upgrades are performed on-time and under budget.

Technical KnowledgeUnderstand the design basis and basic functionalities of all plant equipment & systems. Drive plant operational efficiency, Evaluate the impact and feasibility of new power plant technologies and operating procedures.

The training program and courses are derived from task categories described in Table 1. These task categories are reviewed every three years as a minimum to keep the training program up-to-date with OM changing roles and responsibilities. These major responsibility categories are grouped into four training areas: Technical, Business Acumen, Leadership and On-the-Job Training as described in Curriculum Development.

5.2 Curriculum DevelopmentFour curriculum tracks have been established to improve training efficiency. These tracks are based on the different plant technologies that OMs manage for the GO&MS business. The track approach to the curricula lets OMs focus their training effort on the concepts and content most applicable to their sites.

The four curriculum tracks are:

• O&M OM Qualification – Heavy Duty Gas Turbine Combined Cycle.

• O&M OM Qualification – Heavy Duty Gas Turbine Simple Cycle

• O&M OM Qualification - Aero Gas Turbine

• O&M OM Qualification - Non-Gas Turbine Power Plant

OMs that transfer to a new site with different technologies will be assigned the appropriate curriculum. Once the new training is assigned, the OM must complete it within 12 months.

Operations Manager Training Guidelines and Qualification

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Training Process4





• Business AcumenThis non-technical training describes all internal GE processes, systems and tools OMs use to perform major contract tasks. These include but are not limited to contract knowledge, and business process. This portion of the training is the same for all four qualification curricula within training program. For the latest list of Business Acumen courses, see Attachment #1.

• Leadership TrainingOMs need very strong communication, team performance and technology-driven leadership skills to succeed in an environment with constant interaction between man and sophisticated machinery and where customers are vigilant of all aspects of contract fulfillment and delivery. Leadership training enables OMs to support key business initiatives, keep pace with changing business requirements and model GE values. It also enabl

O&M Training Playbook - Robert J. Allenrobertjallen.yolasite.com/resources/Desktop Publishing.pdf · 2012. 9. 25. · GE Energy | O&M Training Playbook (06/2012) 1-1 1 Prologue This

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