O&M Training Playbook

Transcription

1 O&M Training Playbook GE Energy Power Generation Services O&M Training Playbook 2012, General Electric Company. All rights reserved. GEA19964 (05/2012)

2 1 Prologue 1 Prologue

3 1 Prologue 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. 1-1

4 2 Plant Manager Training Guidelines and Qualifications 1.0 Purpose and Scope 2.0 Definitions 3.0 Roles and Responsibilities 3.1 O&M Training Manager 3.2 Region Manager 3.3 Mentors 3.4 Plant Manager Candidate 4.0 Policy 5.0 Training Process 5.1 Planning and Design 5.2 Curriculum Development 5.3 Major Training Categories 5.4 Execution 5.5 Training Exemption Requests 5.6 Continuing Training 5.7 Training Review 6.0 Management Review Requirement Summary 7.0 References Attachment 1 - Plant Manager Curricula Attachment 2 Plant Manager Qualification Cards 2 Plant Manager

5 2 Plant Manager Training Guidelines and Qualification Purpose and Scope 1.0 Purpose and Scope Plant 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 DOE EHS FERC GO&MS mylearning NERC OJT OSHA PGS PM QAP Qualification RBM TRB Contractual Services Agreement Department of Energy Environmental Health & Safety Federal Energy Regulatory Commission Global Operations & Maintenance Services GE Energy Corporate Learning Management System North American Electric Reliability Corporation On the Job Training Occupational Safety and Health Administration Power Generation Services Plant Manager Quality Assurance Procedure Business acknowledgement that an employee has fulfilled all training requirements defined for employee s role or position Reliability Based Maintenance Training Review Board 3.0 Roles and Responsibilities 3.1 O&M Training Manager The 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 Manager The 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. 2-1

6 2 Plant Manager Training Guidelines and Qualification Policy 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 Mentors Mentors 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 Candidate PMs 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 Policy The 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 Process Plant 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 Design Table 1 indicates the terminal training objectives with respect to the PMs main role and responsibilities. Table - 1 Responsibility Category Contract Management Contract Financials Contract Operations Terminal Training Objective Understand the scope and content of their O&M contract. Effectively fulfill all contract requirements. This includes negotiation of concessions and extra work orders. Manage and drive all financial aspects such as budgets, costs & billing and margin review. Track financial health of their contract to support contract profitability. Execute contract activities and functions such as outage planning, customer reporting and customer and personnel meetings to fulfill contract requirements. 2-2

7 2 Plant Manager Training Guidelines and Qualification Training Process Responsibility Category Stakeholder Relations GE Internal Processes Law & Regulations Plant Maintenance Plant Operations Project Management Technical Knowledge Power Market Terminal Training Objective Manage customer and labor relations. Manage & Improve personnel performance by effectively leading and developing their overall skills and technical knowledge. 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. Understand 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. Understand 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). Understand and lead plant day-to-day operations. Drive consistent usage of plant operational procedures. Promote collaboration between the operations and maintenance teams. Manage 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. 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. 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 Development Four 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 Training This 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. 2-3

8 2 Plant Manager Training Guidelines and Qualification Training Process Business Acumen This 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 Training PMs 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 # 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 Requests When 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: Continuing Training Continuing 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 Review An 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 2-4

9 2 Plant Manager Training Guidelines and Qualification Management Review Requirement Summary 6.0 Management Review Requirement Summary The following management reviews must be conducted and documented. [Table QAP ] Management Review Requirement Summary Frequency Responsiblitoy Item Notes Annual Annual Annual PGS Quality Program Manager, Manager O&M Training O&M Operations Leader O&M Operations Leader Review this instruction for applicability. Participate in Training Review Meeting Conduct Training Review Meeting 7.0 References GEEQMS 6.2.2, Competence, Awareness and Training O&M Quality Assurance Procedure 007 Staffing &Training 2-5

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11 2 Plant Manager Training Guidelines and Qualification Attachment 1 Plant Manager Curricula 2-7

12 2 Plant Manager Training Guidelines and Qualification Plant Manager Training Curricula Training Courses: Aero Combined Cycle Simple 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 GEPS-HR-HR0010-CS Invoicing and Billing Responsibilities of a Contract Performance Manager (CPM) 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 2-8

13 2 Plant Manager Training Guidelines and Qualification Aero Combined Cycle Simple Cycle Non-Gas Turbine Technical Courses GEAERO-PROD-TECH-105 FAM LM2500 GT GEAERO-PROD-TECH-106 FAM LM6000 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 GEPS-ENG-TECH008-CS GEPS-ENG-TECH009-CS GEPS-ENG-TECH019-CS GEPS-ENG-TECH020-CS GEPS-ENG-TECH038-CS PATAT 16 - Troubleshooting Liquid Fuel System Problems PATAT 3 - GT Exhaust Gas Thermocouple Installation PATAT 4 - Generator Brush Inspection & Maintenance PATAT 10 - Drum Level 3: Condensate and Feedwater Pump Systems PATAT 11 - Drum Level 4: Bypass Systems Course PATAT 1- PATAT Indoctrination for GE Energy Employees and Customers GEPS-ENG-TECH052-CS PATAT 7 - HRSG Operation and Maintenance 2-9

14 2 Plant Manager Training Guidelines and Qualification Aero Combined Cycle Simple Cycle 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-CS GER-3620: Heavy-Duty Gas Turbine Operating and Maintenance Considerations - Technical Leadership Courses GEE-PSKL-FLL-PGS Front Line Leadership Skills 2-10

15 2 Plant Manager Training Guidelines and Qualification 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

16 2 Plant Manager Training Guidelines and Qualification Introduction Introduction As 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: Release: 1.0 Date and Version of Release Description First Release of the Qualification Card and Standards document. Roles and Responsibilities Roles O&M Training Manager Mentor Region Manager (of the PM candidate) Candidate Responsibilities Maintain this document, procedures, and guidelines Ensure secure storage of all completed OJT checklists 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 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 Complete the tasks listed in the OJT Handout Processes and Standards As 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 openended 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. 2-12

17 2 Plant Manager Training Guidelines and Qualification Processes and Standards 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, Simulate and Perform: : 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 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. 2-13

18 2 Plant Manager Training Guidelines and Qualification Processes and Standards Task Description OJT Tasks Handout Contract Financials Level Mentor Initials/Date 1. Explain the revenue recognition principles for O&M contract. 2. Conduct a Margin Review using ICAM (If applicable) 3. Validate contract model using ICAM (If applicable) 4. Analyze the Catalog reports (If applicable) 5. Analyze the Comparison reports (If applicable) 6. Analyze the Count reports (If applicable) 7. Analyze the Forecast reports (If applicable) 8. Prepare S2 for site. 9. Assess contract performance & profitability. Contract Management 10. Assess plant operation and CM&Us opportunities to determine extra-work opportunities. 11. Support Sales, Comm Ops and engineering in developing GE offerings for repair, parts, and services Extra Work. Contract Operations 12. Locate project documents using ProjectNet (Customer Collaboration). 13. Generate the purchase orders for parts and services required using the Demand Placement process. 14. Coordinate with the third-party vendor in purchasing consumables. 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. 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 2-14

19 2 Plant Manager Training Guidelines and Qualification Processes and Standards Task Description Contract Financials Level Mentor Initials/Date 23. Create a customer invoice. Perform 24. Explain the payment procedures followed by the customer for your O&M contract. 25. Define the roles and responsibilities of each player in the outage planning process. 26. Explain the contractual requirements for O&M outages 27. List the milestones in the Outage planning process. 28. Follow QWI to execute a Forced Outage Complete ORAP DOE/FERC/NERC regulatory reports as applicable. Perform GE Internal Processes 29. Explain the significance of Policy Explain the significance of Policy Describe the scope, authority, and level of confidentiality of a DCI. (Design Change Instruction) 32. Describe the scope, authority, and level of confidentiality of an ECN. (Engineering Change Notification) 33. Describe the scope, authority, and level of confidentiality of a PMI. (Field Modification Instructions) 34. Describe the scope, authority, and level of confidentiality of a GEH. (GE, External Complete Instructions) 35. Describe the scope, authority, and level of confidentiality of a GEI. (GE, External Instructions) 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.) 37. Describe the scope, authority, and level of confidentiality of a GER. (GE, Reprint) 38. Describe the scope, authority, and level of confidentiality of a TIL. (Technical Information Letter) 39. Describe the scope, authority, and level of confidentiality of a TIM. (Technical Information Memo) 40. Describe the scope, authority, and level of confidentiality of a Hot List Item. 41. Describe the scope, authority, and level of confidentiality of the Top Issues List. 42. Describe the scope, authority, and level of confidentiality of a Fact Sheet. 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) 2-15

20 2 Plant Manager Training Guidelines and Qualification Processes and Standards Task Description Contract Financials Level Mentor Initials/Date 44. Create an opening letter to initiate P&RS services. General 45. Retrieve documents from PLM 46. Use efield Services as needed by your contract. 47. Use eps (Product Services Portal) as needed by your contract. 48. Use erfq (Request For Quote) as needed by your contract. 49. Use ewarranty as needed by your contract. 50. Use GE PartsEdge as needed by your contract. 51. Use PowerSmarts as needed by your contract. 52. Use Product Service Web Page as needed by your contract. 53. Use PAC/Clarify to raise/resolve issues. Law & Regulations 54. Control GE "Proprietary" information in your possession. 55. Explain the circumstances that might require GE Legal assistance. 56. Explain the legal issues surrounding regulatory reporting. 57. State the criteria under which documentation is designated as "Proprietary". 58. Apply governmental laws and regulations for facility operation (e.g. environmental discharges, wildlife, labor law/relations, OSHA, EU directives, etc). 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 61. Explain parameters to be monitored/recorded while unit is running (GER-3620) 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. 2-16

21 2 Plant Manager Training Guidelines and Qualification References Task Description Level Mentor Initials/Date Contract Financials 64. Explain the legal risk associated with communication & documentation related to O&M contracts. 65. Analyze NPS survey results and create an action plan. 66. Create CIR (Customer Issue Resolution Module). Technical Knowledge 67. Understand purpose & function of OSM (On Site Monitoring). 68. Understand purpose & function of OSM (On Site Monitoring). 69. Understand factors that impact Plant Performance / Heat Rate. 70. Use EMAP (plant optimization software) to optimize plant performance. 71. Identify and share site best practices and corrective actions with the fleet. 72. Perform RCA and corrective actions and understand relationship to plant & fleet reliability PM Signature SSO Date Mentor Signature SSO Date When complete, mail a copy of (or scan and ) this checklist to energy.pgs.pmtraining@ge.com to be recorded in mylearning. 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, the candidate should the queries to: energy.pgs.pmtraining@ge.com 2-17

22 3 Maintenance Manager Training Guidelines and Qualification 1.0 Purpose and Scope 2.0 Definitions 3.0 Roles and Responsibilities 3.1 O&M Training Manager 3.2 Region Manager 3.3 Plant Manager 3.4 Mentors 3.5 Maintenance Manager Candidate 4.0 Policy 5.0. Training Process 5.1 Planning and Design 5.2 Curriculum Development 5.3 Major Training Categories 5.4 Execution 5.5 Training Exemption Requests 5.6 Continuing Training 5.7 Training Review 6.0 Management Review Requirement Summary 7.0 References 7.1 Introduction 7.2 Version History 7.3 Roles and Responsibilities 7.4 Processes and Standards 7.5 Queries and More Information Attachment 1 Maintenance Manager Curricula Attachment 2 Maintenance Manager Qualification Cards 3 Maintenance Manager

23 3 Maintenance Manager Training Guidelines and Qualification Purpose and Scope 1.0 Purpose and Scope Maintenance 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. 2.0 Acronyms and Definitions CSA DOE EHS FERC GO&MS mylearning NERC OJT OSHA PGS PM QAP Qualification RBM TRB Contractual Services Agreement Department of Energy Environmental Health & Safety Federal Energy Regulatory Commission Global Operations & Maintenance Services GE Energy Corporate Learning Management System North American Electric Reliability Corporation On the Job Training Occupational Safety and Health Administration Power Generation Services Plant Manager Quality Assurance Procedure Business acknowledgement that an employee has fulfilled all training requirements defined for employee s role or position Reliability Based Maintenance Training Review Board 3.0 Roles and Responsibilities 3.1 O&M Training Manager The 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 Manager The 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: Advise and approve the program established by O&M Training Manager. Designate certified PMs under their direction to serve as mentors for qualification candidates as needed. 3-1

24 3 Maintenance Manager Training Guidelines and Qualification Policy 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 training plan, support the development process, and ensure completion of the training curriculum. Serve as instructors as needed. 3.3 Plant Manager The 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 Mentors Mentors 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: Serving as Instructors for the formal training program as requested. Creating training material for the MM training program when assigned to do so by their Manager. 3.5 Maintenance Manager Candidate MMs 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 Policy The 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. 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 Process Maintenance 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 Design Table 1 indicates the terminal training objectives with respect to the MMs main role and responsibilities. 3-2

25 3 Maintenance Manager Training Guidelines and Qualification Training Process Table - 1 Responsibility Category Contract Management Contract Operations Stakeholder Relations GE Internal Processes Law & Regulations Plant Maintenance Project Management Technical Knowledge Terminal Training Objective Understand the scope and content of their O&M contract such that they can equitably fulfill contract requirements. Participate in contract activities and functions such as outage planning, customer reporting and customer and personnel meetings so that contract requirements are fulfilled. Manage customer and labor relations. Improve personnel performance by effectively leading and training them to improve their overall skills and technical knowledge. 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. Understand 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. Understand 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). Manage 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. 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. 3-3

26 3 Maintenance Manager Training Guidelines and Qualification Training Process 5.2 Curriculum Development Four 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. 5.3 Major Training Categories All four tracks contain four major task categories. Technical Training This 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. Business Acumen This 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 Training MMs 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 # 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 Requests When 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. 3-4

27 3 Maintenance Manager Training Guidelines and Qualification Management Review Requirement Summary The Training Exemption request work flow (WF) process can be started from the PGS Training Community Support Central site under Process at: Continuing Training Continuing 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 Review An 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 Summary The following management reviews must be conducted and documented. [Table QAP ] Management Review Requirement Summary Frequency Responsibility Item Notes Annual Annual Annual PGS Quality Program Manager, Manager O&M Training O&M Operations Leader O&M Training Manager Review this instruction for applicability. Participate in Training Review Meeting Conduct Training Review Meeting 7.0 References GEEQMS 6.2.2, Competence, Awareness and Training O&M Quality Assurance Procedure 007 Staffing &Training 3-5

28 3 Maintenance Manager Training Guidelines and Qualification References 3-6

29 3 Maintenance Manager Training Guidelines and Qualification Maintenance Manager Curricula Attachment 1 Maintenance Manager Curricula 3-7

30 3 Maintenance Manager Training Guidelines and Qualification Maintenance Manager Curricula Maintenance Manager Training Curricula Training Courses: Aero Combined Cycle Simple 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 GEPS-HR-HR0010-CS Invoicing and Billing Responsibilities of a Contract Performance Manager (CPM) 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 3-8 GE Energy O&M Training Playbook (05/2012)

31 3 Maintenance Manager Training Guidelines and Qualification Maintenance Manager Curricula Aero Combined Cycle Simple Cycle Non-Gas Turbine Technical Courses GEAERO-PROD-TECH-105 FAM LM2500 GT GEAERO-PROD-TECH-106 FAM LM6000 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 GEPS-ENG-TECH004-CS PATAT 13 - Compressor Bleed Valve System 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 GEPS-ENG-TECH008-CS GEPS-ENG-TECH009-CS GEPS-ENG-TECH019-CS GEPS-ENG-TECH020-CS GEPS-ENG-TECH038-CS GEPS-ENG-TECH052-CS GEPS-ENG-TECH054-CS PATAT 16 - Troubleshooting Liquid Fuel System Problems PATAT 3 - GT Exhaust Gas Thermocouple Installation PATAT 4 - Generator Brush Inspection & Maintenance PATAT 10 - Drum Level 3: Condensate and Feedwater Pump Systems PATAT 11 - Drum Level 4: Bypass Systems Course PATAT 1- PATAT Indoctrination for GE Energy Employees and Customers PATAT 7 - HRSG Operation and Maintenance PATAT 5 - High Exhaust Temperature Spread GEPS-ENG-TECH055-CS PATAT 12 - Bearing Lube Oil & Hydraulics 3-9

32 3 Maintenance Manager Training Guidelines and Qualification Maintenance Manager Curricula Aero Combined Cycle Simple Cycle 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-CS GER-3620: Heavy-Duty Gas Turbine Operating and Maintenance Considerations - Technical GEE-PGS-OPS-TECH-001 Leadership Courses Reliability Based Maintenance Implementation 3-10 GE Energy O&M Training Playbook (05/2012)

33 3 Maintenance Manager Training Guidelines and Qualification Maintenance Manager Qualification Cards 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

34 3 Maintenance Manager Training Guidelines and Qualification Maintenance Manager Qualification Cards Introduction As 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: Release: 1.0 Date and Version of Release Description First Release of the Qualification Card and Standards document. Roles and Responsibilities Roles O&M Training Manager Mentor Region Manager (of the MM candidate) Responsibilities Maintain this document, procedures, and guidelines Ensure secure storage of all completed OJT checklists 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 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 Standards As 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 openended 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, Simulate and Perform: : 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. 3-12