Prasanna P

Senior Thermal Design Engineer with 4+ years of experience in heat transfer, secondary flow systems, aerothermal analysis, and thermal design of gas turbine components. Experienced in developing and validating thermal network models, CFD simulations, and thermo-mechanical analyses for rotating and stationary turbomachinery components across aircraft engine programs. Strong expertise in thermodynamics, fluid mechanics, heat transfer, and gas turbine cooling systems with hands-on experience using Flow Simulator, SPAN, NGT, ANSYS Fluent, HyperMesh, and thermal network methodologies.

Proven ability to independently execute thermal design and analysis activities, evaluate design trade-offs, perform root cause investigations, and deliver engineering recommendations supporting product development, certification, and technology maturation programs.

Senior Engineer - Alten India

(2024-09)

Project: Rolls-Royce Thermals (Trent XWB – 97 Baseline)

• Independently led thermal design and secondary air systems-thermal analysis activities for gas turbine secondary flow systems supporting Trent XWB-97 engine programs.
• Developed and validated thermal network models using SPAN and Flow Simulator to predict cooling flow distribution, heat transfer characteristics, and component metal temperatures.
• Executed thermal analysis of rotating and stationary engine components under transient operating conditions, improving temperature prediction accuracy by approximately 15%.
• Performed thermal and thermo-mechanical assessments of HPC adverse hardware conditions to evaluate thermal margins, component life, and certification compliance have ownership of adverse modelling tasks, and arrived at adverse seal clearance for IPT adverse seal conditions.
• Conducted design trade-off studies and sensitivity analyses to assess thermal performance and identify robust design solutions.
• Supported design reviews by providing technical recommendations, thermal risk assessments, model assumptions, validation results, and engineering conclusions.
• Validated thermal modeling methodologies during on-site assignment at Rolls-Royce UK, ensuring consistency between analytical predictions and engineering requirements.
• Contributed to continuous improvement of thermal modeling methodologies and analysis workflows, reducing model setup effort and improving consistency.
• Reduced model run time through parallel work flow ensuring reduced down-time to run transient analysis

Engineer - Quest Global Pvt. Ltd.

(2023-07 - 2024-09)

Project: GE Thermals (LEAP 1B, RISE)

• Performed 1D network analysis for fluid flow and heat transfer in gas turbine air and fuel systems, supporting mechanical system assessment and integrated design studies.
• Executed multi-domain thermo-mechanical FEA models that improved deflection prediction accuracy by about 10%, increasing confidence in analysis outputs.
• Supported FNS-to-FI model conversion, enabling integrated system simulation across engine subsystems and improving coordination between engineering functions.
• Worked closely with engine performance, turbine, compressor, combustion, and controls teams to resolve system-level issues and support project delivery.

Engineering Apprentice - GTRE, DRDO

(2022-05 - 2023-06)

Project: Engine Thermals (ATGG)

• Independently conducted CFD and conjugate heat transfer analysis of secondary air systems in 2D and 3D, improving metal temperature prediction accuracy by about 15%.
• Conducted thermal design and heat transfer assessments of gas turbine fuel systems under transient and steady-state operating conditions to evaluate thermal margins and system performance.
• Analyzed compressor and turbine thermo-fluid behavior, identifying critical temperature gradients and performance limitations for engineering assessment.
• Calibrated experimental rig equipment to improve data acquisition reliability and support accurate validation results.

Graduate Engineering Trainee - Rishi FIBC - Mysore

(2021-07 - 2022-02)

• Applied Lean manufacturing principles (SMED, standard work, waste reduction) to improve production efficiency, achieving 5% increase in throughput.
• Implemented SMED (Single-Minute Exchange of Dies) methodology, reducing machine downtime by 18% through optimized tooling changeover processes.
• Developed and standardized Standard Operating Procedures (SOPs) to enhance process consistency, reduce variability, and improve product quality.
• Led a team of 30+ technicians/operators, driving process optimization and continuous improvement initiatives on the shop floor.
• Supported extrusion tape dimensional tolerancing, quality inspection, and manufacturing process control, ensuring adherence to engineering and quality standards.
• Improved equipment utilization and manufacturing efficiency by applying core mechanical engineering principles to tooling and process design.

Engineering Intern - Bhoruka Fabcons Pvt Ltd - Mysore

(2021-01 - 2021-04)

• Contributed to New Product Introduction (NPI) by leading development of a mechanical product (exercise bow).
• Executed concept design, structural analysis (FEA), material selection, and manufacturing planning.
• Performed stress and deformation analysis to ensure product reliability under cyclic loading.
• Managed procurement and supported prototype development through to final production lifecycle.

Bachelor of Engineering - Mechanical Engineering - Christ University (2017 - 2021)