Lead Test Rigs Design Engineer - Testing

About The Role : Summary GE Gas Power Component Develoopment Testing (CDT) team design and develop state of art rigs to perform various tests for GE Gas Power, GE Vernova and external Customers. These rigs are built to test full scaled components or scaled down components and involves rotating rigs, stationary rigs, high temperature and high pressure rigs and with sophisticated instrumentation included. The success of these rigs and the tests depend on careful design considerations, proper commissioning and by adopting safer testing procedures. In the current role, the Lead Design Engineer owns the technical ownership of designing variety of these rigs, oversee the rig commissioning activities, make sure smoother test execution and enable the commissioning & decommissioning activities. The Lead Design Engineer should also work closely with all the stakeholders during various phases of the project including the evaluation, planning, execution, documentation, and ensuring the ISO compliance during the execution. The candidate should make the proposals for new RFQs, review the technical drawings, develop method books and standard operating procedures for variety of tests to be conducted in the lab. The candidate should interact with Suppliers/ manufacturers during the procurement/ manufacturing phases and ensure that the end product meets the customer CTQs/ design requirements. In addition, the candidate should also mentor/ guide young engineers, and the lab technicians.



About The Role :

Roles and Responsibilities

Lead the customer sponsored test programs in test rig design, manufacturing, build, teardown & test operations. Act as a primary interface between the customer, the testing team and the leadership team for smooth communication.

Understand the test vehicle requirements/ CTQs, existing lab/ facility capabilities & collaborate with the customers to firm up the design requirements. Make the technical proposals accordingly and pitch in with the Customer/ stakeholders.

Review the test rig upgrades & own the design reviews/ action items. Track/promote assigned AIs & DRs in electronic reporting/tracking systems (PLM).

Work closely with TLs, TE/FE, technicians, & external man power and identify potential areas of improvement and implement the same.

Provide technical oversight & critical review of test H/W, instrumentation, test rig capability vs. TR requirements.

Deliver technical presentations at design reviews & program reviews (safety reviews, red flag reviews, and similar). Track/close AIs in PLM.

Actively engage in test planning across internal functions and external functions (e.g. Customer, SFO, Design Team, vendors, and similar).

Prepare/review test rig build & teardown documentation including: Build Books, clearances, thrust, alignment, & other inspections documentation.

Provide technical guidance & work planning direction to a team of 4-6 test engineers/specialists. Provide technical guidance to crafts resources supporting teardown/build activities.

Review the technical drawings and ensure that these drawing meet the design intent. To work closely with manufacturers / suppliers to get the right material/ manufacturing as per the requirements. To check on the incoming raw material, inspection reports, NDT reports at various stages of manufacturing and act on the deviations/ misses accordingly.

To perform RCA and identify possible reasons for discrepancies/ abnormalities. To provide quick fixes to enable the tests.

Provide feedback to individuals and provide objective-based performance input during the team appraisals.

Mentor/develop junior TE/FE in designing/ testing aspects.

Problem solving mindset, should take quick decisions to enable high say/do ratio without compromising on safety. Should talk to SMEs to enable these solutions with quick turnaround times.

To look for new areas of expansion, work closely with PL/TL to enable testing in new areas of expansion.

Maintain ISO compliance.

Required Qualifications

BS/MS degree in Mechanical/ Aerospace Engineering or related technical discipline from reputed university.

Minimum of 10+ years experience in design and analysis, especially focusing on rotating equipment and/or structures/component design, turbine/compressor/rotor engineering, power plant knowledge, fluid-structure interactions, industrial machine manufacturing, instrumentation and/or multi deciplanary laboratory testing skills.

Working experience with design and analysis tools including ANSYS Classic, ANSYS WB, Unigraphics, other structural/ fluid analysis software.

Cognizant with ASME and other codes and standards

Familiar with PLM and standard NPI or equivalent processes

Working experience on making proposals, uncertainty analysis,

Experience with Lean and Six Sigma tools and processes.

GB certified (GE employees only).

Knowledge on GDT, manufacturing aspects (welding, machining), NDT procedures

Desired Characteristics

Experience in steam turbine technology, gas turbine technology, mechanical, performance, high temperature and pressure, and/or other laboratory testing.

Six Sigma DFSS BB Certified (GE employees only).

Knowledge of pressure vessel design, test methodologies, Instrumentation routing mothods/ technics, test instrumentation and measurement systems, power plant and process equipment, data acquisition system and data processing.

Knowledge in SAFER, HazOp, Design Reviews, Red Flag Reviews, Test Record Files, Data system equipment.

Strong technical communication (verbal and written).

Ability to lead and mentor Test/Facility Engineers & Test Specialists.

Commitment to customer, teamwork and for team success.