Tampa Granite July 2015 Final

Granite Conference
PSE Presentation
July 8, 2015 – Tampa, FL
Imagination at work
GE Proprietary Information—Class III (Confidential)
Export Controlled—U.S. Government approval is required
prior to export from the U.S., re-export from a third country,
or release to a foreign national wherever located.
Presenter
Mark Knowles:
Product Service Engineer (Tampa, FL)
Purdue University – Grad 1985
BS Aviation & Mechanical Engineering Technology
29 years @ GE supporting DP Aero LM Family Products
Cincinnati Test cell 1985 - 1989
Field Service Rep 1989 – 1995
Field Service Tampa Regional Mgr 1996 - 2005
Product Service Engineer 2005 - Present
e-mail: [email protected]
Cell : 813-477-4835
2
Intro to Product Service Engineering
July 2015
3/
GE /
July 8, 2015
Main Topics
- Who is PSE ?
- DP Gas Turbines footprint & products
- What does PSE do ?
-
-
Fleet Support – Transactional & CSA problem solving
(I&C) Installation & Commissioning
FER (Field Event Reporting)
CM&U (Controls, Mods, Upgrades)
Service Center Support
PSE Expectations of Field Service
Service Now FS Reporting
Necessary tools
Your Growth
4/
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July 8, 2015
Who is
Product Service Engineering ?
PSE - Who are we ?
Investigation
Testing
+
• Data Driven Solutions
6/
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July 8, 2015
DPE Services Organization Chart
Services Engineering
General Manager
David Harper
The Distributed Power Services Engineering team partners
with DP Global Services to provide
world class technology solutions to our customers
throughout the product life cycle.
Analytics
Matt Krueger
•
•
•
•
RM&D/Analytics
Performance
Fleet Data Management
Analytic and Data Tools
Life Cycle
Engineering
Jim Drees
•
•
•
•
•
DPE-S
Condition Based Maintenance
Reliability Engineering
Repair Engineering
Depot Support (Global)
Parts COE
Regional Leader
North America
Dave Boudreaux
Regional Leader
Latin America
Carlomagno Rivas
GT COE
- Controlled Title Holders
- GT PSE COE
- GT CM&U
Regional PSE
Depot Support (Houston)
Regional CM&U App Engr
•
•
•
Regional PSE
Depot Support (Brazil)
Regional CM&U App
Engineer
Regional Leader
Europe
Michael Förster
RE COE
- RE PSE COE
- RE CM&U
Regional PSE
Depot Support (Rheden)
Regional CM&U App Engr
Regional Leader
MEATI
Satish Krishna
•
•
Regional PSE
Regional CM&U App
Engineer
Regional Leader
Asia
Satoshi Enamito
•
•
Regional PSE
Regional CM&U App
Engineer
7/
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July 8, 2015
DP Service Engineering
Manager – North America Region
DP Services Engineering
General Manager
David Harper
Recip. Engines
Atlanta
David
Boudreaux
Ryan Smith
Waukesha
PSE
Cincinnati
NA DP GT
Manager
Edison/
Interns
David
Bacchus
Houston
Johnny
DeMent
Missouri
Mideast
Region
Jimmy
Simmons
Florida
Controls,
combustion
& operability
John
Heaton
Houston
NE Region
Rachel
Danek
Houston
Western
Region
Mark
Knowles
Florida
Alaska /
Cruise ships
PLE/PE
FER / Depot Support
Manager
Nate Yux
Adriana Henao
Houston
Zack Olds
Houston
U. of Fl
Jacob Lozano
Houston
TAMU
(Start June 1)
Amanda
Scotto
Houston
Edison
(Start June 22)
Bob
Wiley
Cincinnati
RCA team
TBD
Houston
DSE
Dan
Heitzman
Ike
Bartlett
Missouri
Canadian
Region
Richard
Driscoll
Houston
Electrical Design
Judson
Knowles
Colorado
Midwest
Region
Joshua Warren
Houston
Edison
(Start July 13)
Houston
DSE
Cincinnati
LM2500 PL
Lead
Dave Brownell
Florida
LMS100 PL Lead
Chuck
Genenbacher
Cincinnati
LM6000 PL
Lead
Randy Shinkle
Cincinnati
Controls
Principal Engineer
Kumar
Khemchandani
Cincinnati
CSA/ AM Support
BELCAN FER Support
team (Contractors)
* 8 FTE
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July 8, 2015
DP GT PSE North America
Canada
146
Mark
Knowles
Ike
Bartlett
281-635-3866
813-477-4835
7
3
21
4
3
Rachel
Danek 11 Judson
10
28
832-266-7326 Knowles
185
281-546-6147
32
7
6
6
Johnny
10
3Dement
42
51
10
13
281-221-8259 13
8
10
3
9
13
62
12
6
4
6
Judson = 168
Rachel = 189
John H. = 187
Ike =153
Johnny = 175
Mark = 21 + cruise/backup all regions
Jimmy = 0 (backup)
Randy = 0 (backup)
29
4
2
7
15
15
25
17
5
4
2John
4
Heaton
832-627-1108
20
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July 8, 2015
DPE GEIQ PSE Organization Chart
Services Engineering
General Manager
David Harper
The Distributed Power Services Engineering team
partners with DP Global Services to provide
world class technology solutions to our customers
throughout the product life cycle.
Regional Leader
Latin America
Carlomagno Rivas
PSE / CoE Parts Manager
Latin America
Fernando Bonilla
Principal Engineer
Latin America
Javier Ramirez
Seniorl Engineer
Latin America
Jaime Rodriguez
Material Lab Leader
Mexico & CA.
Cesar Vazquez
PSE CSA & TX Leader
Mexico & CA.
Benjamin Ortega
TM 2500 leader
Latin America
Gustavo Gonzalez
PSE TX Leader
South America.
Alberto Hinojosa
PSE Engineer
I&C NA and LATAM
Rene Alanis
FI leader
Latin America
Alfonso Cardenas
PSE Engineer
LATAM Support
Jose A. Guerrero
PSE Jenbacher
Latin America
Jose Galvan
GE&Proprietary
and Confidential
Information
Privileged
Confidential Information.
Prepared for
the Review of Counsel
Parts CoE Engineer
Victor Medina
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July 8, 2015
PSE LATAM MAP SUPPORT
TM 2500 leader
Latin America
PSE CSA & TX Leader
Mexico & CA.
Gustavo Gonzalez
Benjamin Ortega
PSE TX Leader
South America.
Alberto Hinojosa
PSE CSA Leader
South America
Jaime Rodriguez
GE Proprietary and Confidential Information
Privileged & Confidential Information. Prepared for the Review of Counsel
11 /
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July 8, 2015
GT Service Eng. EU
DPE-S EU
Regional Services
Engineering (Europe)
M. Foerster
GT Service Eng. EU
Tomás Baudin
(Madrid)
FER TL
Karol Kwolek
CM&U
(Warsaw)
Stewart
Henderson
Miguel
Bartolome
(Glasgow)
(Madrid)
Albert
Stajniak
Hanne
Rolloos
(Warsaw)
(Rheden)
Konrad
Syska
José
Rodrigo
(Warsaw)
(RMadridn)
Reg.Support
TL/NE
Install &
Comm. TL
D. Campbell
(Glasgow)
J. de Ceuster
(Rheden)
Paul
Gordon
Andrzej
Wojtowicz
Virgil
Adam
(France) MEA Region
(Warsaw)
(Rheden)
Leon
Nollgen
Radek
Ucinski
Wilco
Smit
(Rheden) CE Region
(Warsaw)
Fred
de Wit
Sergey
Mamyshev
(Rheden) 2nd line + TM I&C
Andy
Crocker
Piotr
Zajac
(UK) 2nd line
(EEDP Warsaw)
Ignacio
Pinedo
Manager
Team Leader
Dotted line report
AÜ
Domingos
Ribeiro
Aran
Sol
Nikolay
Onchukov
Pedro
Benito
(Glasgow))
(Spain) 2nd line & RGB´s
(RMadridn)
(Moscow)
(Warsaw)
Ewan
Wilson
Carlos
Calvo
Andrey
Tarasov
(Spain) SE Region
(Spain) 2nd line TM I&C
Direct line report
(Moscow)
Tomasz
Sawa
(EEDP Warsaw)
(Moscow)
Depot Support
Engineers
(Rheden)
© 2013 General Electric Company - All rights reserved
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July 8, 2015
DP Services Engineering – Service Centers
4 level 4 GE Service Centers
11 authorized service providers
Trans
Canada
Turbines
(TCT)
Service Centers suported by DSE Rheden
MTU Aero
Engines
Standard
Aero (SAE)
GKN
Aerospace
LM1600
PetroChina
IshikawajimaHarim Heavy
Industries (IHI)
Avio, Spa
GE O&G Massa
GE Houston
ITP
Marine
only
Samsung
Aerospace
Industries,
Ltd
GE Brazil
HAL
Marine only
Air New
Zealand
(ANZ)
LM2500
LM5000
GE Service Center
Authorized Service Provider
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July 8, 2015
Significant global footprint
Aeroderivative customers
GE field service locations
GE service centers
Industrial installed base: ~1,800
Global Employees: ~1,600
Total operating hrs: Over 100 million
Field Representatives: ~200
Operating in 55 countries
$1.8B revenue….. $5B by 2015
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July 8, 2015
Aero heritage & applications
Air frame
• Boeing 747, B767
• Airbus A300, A310 & 330
Engine
• CF6-80C2
Aero derivative engine
• LMS100 … 103 MW
Applications
• Power generation
• LM6000 … 42 – 55 MW
• Oil & gas
• Boeing C-5, DC-10
Engine
• TF39/CF6-6
• LM2500+ … 28 – 34 MW
• Mobile power
• LM2500 … 18 - 24 MW
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July 8, 2015
What customers/industries do we serve?
Utilities
– peak power, combined cycle, distributed generation, grid stability
Oil and Gas
– mechanical drive, power generation
FPSO
– offshore power with our compact 538 and 538e packages
Industrial
– combined heat and power
Mobile Power
– emergency power, peak demand, mining and O&G applications
Marine
– on-board power generation and propulsion systems
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July 8, 2015
Electrical Power Generation
Gas Pipeline
Commercial & Military Propulsion systems
Offshore Oil & Gas Exploration
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July 8, 2015
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July 8, 2015
LM6000 PG/PH Technology.
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July 8, 2015
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July 8, 2015
LM2500
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July 8, 2015
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July 8, 2015
1800e technology. 12-16 MW.
24 /
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July 8, 2015
Fleet Support
What is Fleet Support ?
•What we do
• Support technical issues on All Product lines (GT and package),
Other OEM packages, and auxiliaries equipment
• Provide support to both Internal and External customers
• Immediate triage support for installed base
• Provide 24/7 coverage to all sites
• Typically around 4000 Service Now cases a year globally
• KCI (Key Customer Initiative)
•Deep review of customer operating profile
•Equipment breakages & site problems
•Recommend solutions for increased availability
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July 8, 2015
Fleet Support
• PSE Fleet Support oversees the customer equipment & operation through
3 of the phases. During RUN phase we assist the I&C team with reaching
COD and then take over support. We then ensure the customer is
supported throughout the ANALYZE & MAINTAIN life cycle. The “IMPROVE”
phase is supported through the CM&U process.
Improve
Run
Our
Customers
Maintain
Analyze
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July 8, 2015
DP Services Engineering – I&C
Run – Installation & Commissioning
Improve
Our
Customers
Maintain
• Support PM/TA’s (CKOM, PIM, SN, mail, phone)
• Hand off supply chain, delivery, fit-up &
drawing issues to Requisition Engineering
• Assist PM & site team with completion of I&C
Tech Tool, procedures, & manuals
• Improve start-up quality & operational
integrety prior to First Fire
• Drive improvements through Product Line
• Decrease CoQ for the business
• Capture lessons learned (R11)
Analyze
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July 8, 2015
DP Services Engineering – FER
Run
Improve
Our
Customers
Analyze - Field Event Resolution
Maintain
• Provide site containment
• Coordinate with PL/lab/ systems/ hardware
owners
• Leasons learned from FERs hep to prevent other
engines in the fleet
• Provide final report to customer
• Initiate CPR/RCA if necessary
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July 8, 2015
DP Services Engineering - FER
Field Event Resolution
Analysis of a customer site event where the goal is to identify the issue and provide site
containment.
Typical FER should contain:
• Kick-off meeting with the FER team.
• List of site data required for investigation (Site Checklist).
• Short term containment plan.
• Additional depot workscope/ site repair workscope.
• Team meeting when depot findings and all site data available to agreed on next steps.
• Lab workscope (MIR provided to lab).
• Team meeting when all data/ analysis available to agreed on root cause.
• Report drafting and review.
What is FS´s Role In the Process:
• The first on site when the event takes place:
• You will be responsible for data gathering:
• Customer testimony (manage customer input)
• Datalogs / Alarm Screens / Measurements;
• Pictures (never too many);
• Quality reporting;
• Be extremely cautious, whatever FS says first, becomes “absolute truth”
GE job title/30
GE Confidential. Internal use only.
DP Services Engineering – Service Center
Improve
Run
I&C
CM&U
Our Customers
Maintain – Life Cycle
•
•
•
•
•
Maintain units
Increase productivity
Repair technology
Increase intervals
Extend parts life
Analyze
Fleet
support
Depot
FER
31 /
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July 8, 2015
DP Service Engineering - CM&U
Improve – CM&U
• Understand customer needs
• Needs change over time
• Develop new CM&U offerings
• Influence customer
• Quality proposals
• Flawless execution
• Lessons Learned
Run
Our
Customers
Maintain
Analyze
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July 8, 2015
PSE Expectations
of
Field Service
PSE Expectations
• You are our Ambassador for GE Distributed Power !
• Be CONFIDENT in front of customers !
• Always be a LEADER !
• Experts and leaders are not born in a classroom or a cubicle
• Studying good leaders will open your eyes & give insight
• Books, on-line tutorials, movies
• Make the best DECISIONS you can
• Sometimes required with only limited info available
• Develop your problem solving skills – more systems expertise
• Data, logic, analysis, reasoning, & common sense
• Put your hands on the equipment
• Walk the drawings down (oil systems, fuel systems, controls)
• Keep detailed records for potential future use
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July 8, 2015
PSE/CSM Expectations of FS on-site
• Prepare very thoroughly for every job
• Customer DESERVES and EXPECTS preparation
• Read work packages, manuals, previous borescopes, & Service Now case
reports, etc
• Prep any special PPE or tooling
• Talk personally to your CSM about the job – he is who you report to
• Be CONFIDENT in front of customers !
• FS Rep confidence breeds Customer confidence
• Keep your CSM in the loop daily
• Especially if there are technical problems
• Or if there are Customer relations issues
• Or if parts are needed
• Loose lips sink ships
• Negative talk on the job site about previous jobs, tooling, other customers,
family, relationships, or coworkers does not instill customer confidence
• Assume the customer is listening to every conversation
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July 8, 2015
PSE/CSM Expectations of FS on-site
• If a mistake is made……OWN IT ! Then CORRECT IT !
• Workspace cleanliness
• Customers love clean packages & work spaces
• At the end of each shift, tidy up the space & the tools
• Stay for start-up !
• Data collection – did we solve the problem – then prove it !
• Correct leaks ASAP
• Were any new problems created ?
• Take care of the tools !
• Nothing worse than receiving broken tools – EVERYONE LOOKS BAD !
• Talk to your CSM at the end of the job and concur that all deliverables and
expectations have been met PRIOR to departing site
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July 8, 2015
Service Now
ServiceNow
- Changes coming to user input
- “Documentation Only” cases will not change
- All other technical cases to be routed to “Quick Response Center/Level 1”
- More details in the next few weeks
ServiceNow
- Become acquainted with your Customer Service Manager &
Regional PSE…..we’re all on the same team !
- Regular Service Now Cases :
- A ServiceNow case is the tool that we have to communicate on
technical issues with FS and the Service Managers (CPM / TSM)
- FS must always attach measurements & quantify leaks (l/hr)
- PSE does not define unit serviceability, that is FS responsibility
- When does FS open a Service Now Case?
- When the workscope defined in the engine O&M manual & the expertise of
the FS rep has been exhausted and there is still no clear way forward
- When the serviceability limits defined in the O&M Manual are exceeded and
CSM/PSE need to risk assess potential extension of operability
ServiceNow
- Emergency Cases can be submitted :
- When there is going to be a technician on site to provide additional
information and/or execute the collaborated workscopes
- When there is a doubt regarding operability in a well defined unserviceable
condition
- Consult with your CSM to determine necessity of PSE emergency support
- If you need immediate assistance during out of office hours, you MUST call
the Emergency Phone: +1-888-443-7747 or +1-678-844-7747 or the PSE on
duty will not be notified.
Service Now - Creating a SN Case
- Description of the Issue:
-
Define the problem. Be clear & organized. Prepare the data in writing before
submitting the case
-
Add pictures, Alarms Screens, Datalogs, etc.
-
Unit Hours, starts and time since major intervention:
-
-
Collect unit counters and discuss with Service Manager
What troubleshooting has been carried out?
-
-
Describe step by step what has been done and what has been the outcome of
each of the troubleshooting actions
Desired deliverable:
-
Define in which way you need help and provide clear time frame to do so.
Make sure that a method of contact is in the case as the GAL does not have
your cell number
QUALITY OF THE RESPONSE IS EQUAL TO THE QUALITY OF
THE INFORMATION PROVIDED
Service Now - Creating a SN Case – cont’d
Troubleshooting Reporting:
- Identify the Issue:
-
Detailed description of the issue with references to manuals,
hypothesis, troubleshooting performed, & any support information.
- Describe Activities Performed:
-
List the activities performed one-by-one mentioning reference
documentation used
- Report Findings:
-
Following each step of the TS process, reflect the findings in a tidy
detailed manner
Service Now - Creating a SN Case – cont’d
Documentation Only Reporting:
-
Title must reflect the scope of the outage
-
Describe all work activities performed in detail
-
Nothing out of limits found
-
No open technical questions from either the FS Rep or the customer
-
Pictures :
-
Please observe picture quality. After each job, please upload all photos to a folder and attach the
address to the Service Now case.
-
When showing an issue, please add a panoramic picture of the area in which the issue is found, then
the detail.
Panoramic
view
Detail view
Tools
FS Essential Tools
-
DP Services Portal : https://www.ge-distributedpowerportal.com/aeroportal/login.html
-
Gas Turbine Manuals
-
Service Bulletins (engines) / Product Bulletins (package) / Service & Product Letters
-
Bulletin Compliance by Engine Serial Number (ESN) or Package Number
-
IDM (Installation Design Manual): Establishes the packaging requirements for GE LM units)
-
Users Conference Material: Update on engine / package improvement programs
-
Depot Service Reports
-
CWC : https://cwcportal.geae.com/portal/authsec/portal/main/cwcportal-Home
-
-
RM&D: Allows for the download & trending of unit operational data
SIIP : http://siipportal2.energy.ge.com/portal/classic/siip-Home
-
First Fire Tool
-
Unit configuration: Unit model, Generator, Control system, First Fire dates, etc.
-
Depot Reports, SB/PB status, SN / FER history
-
Technical Documents : https://www2.gepower.com/technicalmanuals/html/initSessionTM
-
Site-specific Technical Manuals & procedures relating to I&C
-
Site Specific drawings, catalogues for supplied hardware/assemblies
FS Essential Tools
-
Fuel, Water & Oil Sample Analysis :
http://libraries.ge.com/FoldersData/27031963101/PSE%20Tools%20Portal/PSE%20Tools%20Portal/?fileid=3
83209029101&entity_id=30828952101&sid=101&version=0&encURL=Yes&fileid=383209029101&entity_id=3
0828952101&sid=101&nocache=Mon%20Jul%2006%2015:30:18%20EDT%202015
-
Houston Package Drawings (Enovia) :
https://plmwind.energy.ge.com/aeroplm/common/emxNavigator.jsp
-
APPS : http://supportcentral.ge.com/products/sup_products.asp?prod_id=27828
-
Unit performance simulator: Allows you to run the model of the unit in which you are working in similar operating conditions
providing all thermodynamic cycle parameters. Great comparison tool.
FS Essential Tools (Cont’d)
Site Event Checklists http://libraries.ge.com/foldersIndex.do?entity_id=16093155101&sid=101&SF=1#16093155101
Last Engine/Package Maintenance
(Date & Description) :
Detailed Description of Event
(Symptoms, Sequence of Events, etc):
GE PROPRIETARY INFORMATION - The information contained in this document is GE proprietary information and is disclosed in confidence. It is the
property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation,
it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or configuration
changes or to obtain FAA or any other government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this
notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part. The information contained
in this document may also be controlled by the U.S. export control laws. Unauthorized export or re-export is prohibited.
Total Number of Trips:
Total Number of Emergency Shutdowns:
TSOH (Time Since Overhaul):
TSHS (Time Since Hot
Section Repair/Repalcement) :
TSSR (Time Since Shop Repair):
Total Hours of SPRINT Operation:
m
p
R e l et
q u ed
i re
d
Customer Name:
Site Name:
Engine Serial Number:
Power Turbine Serial Number:
Engine Model:
Event Date:
Total Engine Hours/Starts:
Total Package Hours/Starts:
Total Component Hours/Starts:
Fuel Type:
Emissions Suppression:
Control System Type / Software Version:
Duty Cycle:
Typical Engine Emissions Level:
Typical Engine Inlet Temperature (T2):
Typical Power Level:
Inspect and report findings:
Co
002 Site Event Checklist - HPC Event
X
Datalog of trip (Including High Speed Data of, at a
minimum: LP & HP Speed, PS3, T3, LP & HP Vibration Levels)
X Alarm History Log
X
Performance data for most recent base load/max power
operation (including SPRINT water rates)
X Request Water Wash History
Request Maintenance History (Specifically activities in the
inlet, around HPC Case, VG/VSV Pump/rigging etc)
Water Wash solution sample analysis (if compressor has
X
material build up)
X
X SPRINT/Water Wash water sample analysis
Perform a VSV Lever arm inspection for bent, twisted,
deformed lever arms and document with photos. Inspect
VSV Bushings and document (with photos) the condition.
X
Inspect unison rings and document (with photos) the
condition. Measure the cold rub button gap for each stage
and report to engineering.
Perform inspection of the Air Filter house (document with
X photos) for debris or unusual conditions. Collect any debris
found.
LMS100: Inspect (document with photos) the HPC scrolls,
X
FOD Sock, and witches hat.
X Site gas fuel system P&ID
If any gas compressors at site- provide: type, technical data
sheet
LM6000: Note visual condition of SPRINT nozzles if over
X
12000 hours of operation
X
47 /
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July 8, 2015
Your Growth
Your Growth
• Set challenging goals for yourself
• Example : Get my on-line BS Finance degree in 5 years
• Example : Learn Mark 6e control systems
• Example : Learn a 2nd language
• Devise a plan to exceed them
• Both at a professional and a personal level
• Possible on-line classes (GE internal classes or college credits)
• Leadership, decision making, technical, finance, etc.
• Review goals – evaluate/revise your plan and progress often
• Many career plans “evolve” & that’s OK !
• Always have a “career mentor” to keep you focused
• Develop your “network” of other skilled peers both inside and
outside of the Company
• Develop a 2 and 5 year plan on where you want to be in
“life/career”
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July 8, 2015