EDUCATION AND QUALIFICATIONS

BEng in Mechanical Engineering, University of Portsmouth 1991.

MSc in Computational Fluid Dynamics at the University of Durham (to be completed April 2007). My thesis concerns the development of a multiblock finite volume Euler code in Fortran for unsteady flows in gas turbine intake systems).

RELEVANT SKILLS

Approximately 15 years experience including the following;

Use of linear & non linear finite elements for structural static, dynamic and coupled thermal-structural analysis.

Use of computational fluid dynamics for aerodynamic and heat transfer analysis.

Vibration and acoustic analysis of fixed structures and rotating plant such as gas turbines and turbomachinery.

Data acquisition, signal processing, static and dynamic testing, strain, vibration, pressure & flow measurement.

Computer skills: 2D/3D Modelling: IDEAS, CATIA v4, AutoCAD, Solidworks.

Finite element analysis: ABAQUS, ANSYS & IDEAS.

Computational fluid dynamics: FLUENT, writing of proprietary CFD codes in Fortran.

Other: MathCad, Fortran 90, Visual Basic, Tecplot, nSoft, nVision, MS Office.

EMPLOYMENT HISTORY

2003-2006: Senior Research Engineer, AAF Ltd.

In this role I undertook aerodynamic and structural analysis of gas turbine systems using CFD and Finite Element methods for clients in the power generation industry including Rolls Royce, GE, MHI and Alstom. These typically involved evaluation of differential pressure losses, turbulence and heat transfer and the identification of undesirable phenomena such as flow separation and flow induced vibration. I also undertook site visits to troubleshoot acoustic and vibration concerns relating to the operation of gas turbines and to gather data for the validation of predictive models.

Relevant Skills

Use of CFD methods for the analysis of steady and unsteady aerodynamic flow behaviour including vortex shedding and flow separation. Use of Finite Element Analysis for the evaluation of structural stress and free/forced vibration response due to mechanical or aerodynamic loads. Gathering of pressure and flow data for the validation of predictive models.

2001- 2003: Lead Product Development Engineer, Calsonic Technology Centre Europe

In this role I was directly responsible for undertaking fluid, thermal, structural and vibration analysis of exhaust products and catalytic converters for clients including Mercedes, Jaguar, Land Rover and Lotus. These included the development of lightweight titanium exhaust systems, low heat capacity catalytic converters and the development of non linear finite element analysis and test validation methods for the simulation of structural non linear vibration response. In a commercial capacity I undertook site visits to clients to provide technical expertise and negotiate collaborative development programmes.

Relevant Skills

Linear and non linear structural and thermal finite element analysis using Abaqus and IDEAS. Non linear analysis of flexible decouplers and exhaust system vibration response. In lab and field dynamic testing of structures using electrodynamic and servohydraulic shakers and data acquisition upto 128 channel. Use of time history and frequency based ODS methods to determine structural modal and forced vibration response. Writing of Fortran codes to extract modal parameters such as dynamic stiffness & damping from vibration test data.

1998-2001

Undertaking various contracts in the areas of vibro-acoustic analysis of rotating plant and condition monitoring.

1995-1998

Mechanical Engineer, AMEC Consulting Engineers, Perth, Western Australia

In this role I was responsible for troubleshooting vibration, structural and acoustic problems on rotating plant for clients in the mining, offshore and defence industries. Problems ranged from identification of rotating stall on gas turbines and identification of abnormal vibration on aircraft gas turbines to damage assessment of marine drivetrains and dynamic balancing of rotating plant. In this role I also undertook vibration audits, acceptance tests and commissioning of new plant and the implementation of predictive maintenance and condition monitoring programmes.

In a management capacity I supervised a team of technicians and was responsible for the management, provision and promotion of engineering services to ensure safety, client satisfaction and profitable performance. I also undertook regular liaison with new and existing clients to develop business partnerships and alliances and promotion to maximise business opportunities.

Relevant Skills

Finite element analysis of the static and dynamic behaviour of a wide range of machinery and structures with validation in the field using strain gauge and vibration analysis methods (time history and frequency response ODS).

Condition monitoring and predictive maintenance using vibration analysis, oil analysis and thermography.

Use of FFT spectrum, time waveform, cross phase and modal analysis and operating deflection shape (ODS) methods to diagnose machinery and structural vibration and resonance problems.

Diagnosis of electric motor problems using motor current spectrum analysis.

Diagnosis of noise problems using narrowband noise analysis.

In situ single and dual plane dynamic balancing of rotating equipment such as large industrial fans, ball mills etc.

Acquisition and processing of pressure, noise, temperature, flow, acceleration and strain data.

Root cause analysis and writing of technical reports.

Equipment with which I am familiar include the following:

Power generation plant (steam, gas turbine and diesel driven generators upto 250 MW).

Mining plant (rolls and jaw crushers, reclaimers, conveyors, hammer and ball mills, rotary kilns).

Air handling and water treatment plant (compressors, chillers, condensers, cooling tower fans)

General plant (electric motors, centrifugal and positive displacement pumps, hydraulic drives and gearboxes).

1991-1995

Development Engineer, Research & Development Department, Domnick Hunter Ltd

In this role I undertook the design and development of products for breathing air purification, CO ₂ removal, ultra pure zero air generation and nitrogen generation. I also provided technical expertise to the sales, technical and service departments where I undertook site visits to advise upon new installations and troubleshoot existing installations of gas separation plant.

Relevant Skills

Development of pressure swing molecular sieve and membrane methods for air purification and the generation of gases such as nitrogen and oxygen. Design of electro-pneumatic control systems. Design of pressure vessels to ASME codes. Use of finite elements and solid modelling for product design and optimisation.

PERSONAL QUALITIES

I am highly motivated, proactive, and able to work under pressure as part of a team or under my own initiative. I take an analytical and practical approach to problem solving and can communicate effectively at all levels. I am comfortable working in an office or site environment, during unsociable hours or under difficult conditions and I can offer an enthusiastic and energetic commitment to my work.

Supplementary Information

Brief examples of the types of work I have undertaken are as follows:

AAF LTD.

Computational Fluid Dynamics

Alstom flow induced vibration study.

Following client reports of high duct vibration amplitudes of upto 90 mm/s, in field vibration measurements indicated dominant frequencies of vibration to reside between 31 and 34 Hz. CFD studies were undertaken which indicated vortex shedding to be occurring from the trailing edge of the intake silencer at a frequency of 33 Hz. Using CFD methods an aerodynamic fairing was designed which eliminated the vortex shedding behaviour. Finite element methods were then used to stiffen the fairing structure to optimise the panel and bending modes thereby improving structural durability.

Rolls Royce Trent intake system design.

Use of CFD methods to improve the flow characteristics of the RR Trent intake system. In the original design the intake silencer was located immediately downstream of the intake filtration. Aft of the silencer the airflow passed through a 90 degree elbow and transition with consequent flow separation leading to non uniform velocity and static pressure profiles at the engine intake. Using CFD methods the intake silencer type was changed and repositioned to prevent flow separation resulting in improved flow characteristics, reduced differential pressure losses, a significant cost saving and improved acoustic performance.

Vibration & Acoustic Test

Investigation of noise concerns on board the liner Queen Mary II during sea trials.

During first sea trials the client had reported noise levels exceeding the design specification and submitted a substantial warranty claim. I attended the second sea trials where I undertook acoustic measurements in the gas turbine intake system which confirmed that the client had erroneously recorded broad band flow noise around the microphone tip and that in fact the system was performing to specification, thereby negating the warranty claim.

CALSONIC TECHNOLOGY CENTRE EUROPE

Flow and Thermal Management

Development of a low thermal inertia exhaust manifold.

Euro V legislation required the 'light off' time (50 % conversion efficiency) of the catalytic converter to be reduced to 7 seconds. Whilst mechanisms to achieve this are already known (electric preheating, secondary air injection, engine spark retard), these are a significant on cost, incur a weight penalty and compromise driveability. A low cost, reliable solution is to minimise the thermal inertia of the wetted components pre converter, thereby minimising heat losses from the exhaust gas. I developed a 1D cfd code for the analysis of the flow and thermal characteristics of exhaust manifolds. This was used for sensitivity analyses to determine which parameters (airgap configuration, inner pipe thickness, thermal conductivity, conduction path to structural outer wall, forced convective htc etc.) have the greater effect on gas temperature loss. Validation of the 1D code was undertaken using engine dyno tests.

Structural Analysis

Thermally durable 4 into 1 exhaust manifold

Tubular exhaust manifolds offer improved flow and heat transfer characteristics, however they suffer from thermal fatigue. To investigate ways to improve durability I undertook transient thermal-structural analyses simulating the engine warm up and cool down cycles. This revealed that the thermal expansions of the branch pipes were resulting in plastic deformation followed by necking of the material cross section upon cool down, leading eventually to crack formation and failure. Adoption of alternative materials (creep resistant ferritic stainless steels) and improved thermal management to control the rate of differential thermal expansion during warm up and cooldown provided improved durability.

Development of improved vibration test and analysis methods.

As part of ongoing development of a non-linear model to predict exhaust system dynamic behaviour I used FEA techniques to redesign many of the existing test fixtures used for electrodynamic shaker tests to increase the fundamental modes to above 500 Hz. This required the development of new test methods and writing of software to generate compliance, mobility and accelerance data from bench and on vehicle tests in order to derive forcing function, dynamic stiffness and damping information required for the non-linear system model.

AUST AMEC TECHNICAL SERVICES DIVISION (WISHAW ENGINEERING )

Vibration Analysis.

Western Power, Kununurra, North West Australia

Vibration levels at newly installed irrigation pumps were declared to be excessive by the underwriter. Vibration amplitude and frequency analysis was undertaken together with time domain operating deflection shape analysis indicated a first mode at x1 running speed. An FEA model was developed and recommendations made to stiffen support structure to change it's natural frequency out of the operating range.

Dynamic Balancing

Performing over 100 single and dual plane in situ balances of a diverse range of rotating equipment ranging from centrifugal and cooling tower fans and blowers to mineral classifiers and wood chopping and meat slicing machinery.

Noise Analysis

Westrail, Bunbury, South West Australia

An objectionable audible tone was reported in the galley area of a passenger train. Narrow band noise and vibration analysis confirmed a correlation between noise tone and output gear mesh frequency for the Voith transmission. FEA analysis confirmed this was exciting the natural frequency of the output gear causing the noise. The solution was to tighten tolerances on the reversing mechanism to improve tooth mesh and reduce the magnitude of the gear mesh frequency such that it did not excite the resonant frequency of the output gear.

Strain Gauging and FEA.

Royal Australian Navy, Fremantle, Western Australia

A naval vessel ( HMAS Torrens ) had run aground causing severe damage to the propeller shafts aft of the A brackets. I led a team undertaking strain gauge measurements intended to verify the extent of damage to the shafts. The strain data enabled adjustments to the plummer block bearings to be made to accommodate alignment changes in starboard shaft. The port shaft was irreparably damaged and had to be replaced. Similar work was also undertaken on HMAS Adelaide during refit.

RobeRiverIron Associates, Cape Lambert, North West Australia

RRIA wished to increase capacity of the shiploader which required a structural integrity assessment to be made. An FEA model was derived to estimate present condition, this was validated in the field by undertaking extensive strain gauge and acceleration measurements. The data gathered were in agreement with the predicted results verifying that the FEA model was correct and thereby enabling structural modifications to be simulated by FEA and recommendations for stiffening the structure to be made.

DOMNICK HUNTER

New Product Development

Zero Air Generator

Development of a new product for the generation of ultra pure laboratory grade reference gas for lab instruments such as Flame Ionisation Detectors and Gas Chromatographs, eliminating the need for costly and inconvenient cylinder gas supplies. I conducted research into the performance of molecular sieves and catalysts to remove contaminants to the required specifications, testing of mechanical items such as compressors and valving and the construction of a prototype for customer demonstration. The zero air generator was found to produce zero gas to a higher purity than that obtained from commercial cylinder ultra zero air at lower cost.

NBC Protection System

Development of a prototype NBC protection system for the Ministry of Defence to remove nuclear, biological and chemical contaminants from an airstream. It was to be fitted to vehicles or building HVAC systems to provide breathable air for the occupants.

Microdryer

Development of a miniaturised low flow air separation product for Total Organic Carbon analysis in the water industry. This required the development of a new PSA cycle to achieve the specified dewpoint criteria and utilised miniaturised valving in order to minimise space envelope and weight.