Manager Project

Rupak Das

*** ****** **., # **

Greenville, SC **615

Phone: 404-***-****

Email: *****@******.***

U.S. Green Card holder

CAREER SUMMARY

Eleven plus years of experience in hands-on design/electro-chemical experimentations, project/program management, NPI/NTI validations, process/simulations and plant operations. Mastered the CFD (Computational Fluid Dynamics) modeling (FEA, FDM & FVM) in predicting optimized performance, design of different turbo-machineries. Expertise includes planning, budgeting, defining of scopes, coordinating projects, decision making, leadership, communication, negotiation, resource allocation, task delegation, supporting cross-functional project teams, and ensuring compliance with laws, standard/best practices, and company policies.

CORE COMPETENCIES

Strategic Business Planning, Rotor designs, Project/Program Management, Component design, Hot Gas Path (HGP), Metal/CMC Bucket/Damper/Nozzle/Shroud design, Ply-level analysis, Compressor components, Gas Turbine component design, Turbomachinary, Budget Planning, Inventory Control, Procurement, Performance Standards, Safety and Compliance, Team Leadership and Mentoring, POs and Quotations, Managing a team and analyzing their performance, Resource Allocation, Critical Thinking, Demand and Supply Forecasting, Scheduling and Planning, Project analysis, Analyzing materials’ failures using field inspections, engineering analysis and experimental testings and New Product Development.

Keywords: Design, Turbomachinary, Gas Turbine, Rotor, Bucket, Nozzle, Vane, Shroud, Georgia Tech., Ph.D., Masters, Fellowship, UA, UAH, Ambassador, DFSS, Manufacturing, Corrosion, Consulting, Aerospace, Industrial, Energy, Government.

ACCOMPLISHMENTS

• Managed to guide the robust path of Environmental Barrier Coatings (EBC) for protecting and continuous improvements of Ceramic Matrix Composite (CMC) substrates, materials selections, as the spokesperson, Program Manager and leader of the whole GE Energy (~ more than $25 M/yr.).

• Designed the first CMC airfoil/metal bucket of GE Energy as one of the prime group contributors (efficiency saving ~$76M).

• Designed on vibratory analysis of 6FA, 6B, 7FA & 9FB bucket systems, modal frequencies and shapes, modal cyclic symmetry (MCS), Campbell diagrams, nodal diameters, HCF/LCF analysis, fatigue failures, airfoils, blades and cooling systems.

• Designed thin-film depositions in nano-scales with thermal/thermo-electric modeling (i.e. conjugate heat transfer, including radiation [SS, DOM, Monte Carlo], convection, conduction modes) used in semiconductor, sensor applications (saving ~ $2M/yr.).

• Led and co-ordinate the GE EBC synergy system of 4 cross-functional diverse EBC sub-groups (total groups have min. 16 experienced EBC personnel from Aviation, GRC or Energy) as Program Manager (Lean Six-Sigma Green Belt certified), controlling ~ $ 90 M/ann.

• Designed a high-performance chemical reactor for studying complex vapor phase and surface chemistries in a Metal Organic Chemical Vapor Deposition (MOVPE/MOCVD) system used in planetary semiconductor processing system, reducing the cost by ~ 35%.

• Managed and process designed Hydrogen-Sulfide (H2S) Absorption Plant, as the primary decision-maker, saving ~ $50,000 eqv.(i.e.by-product of Petrochemical Process Plant).

• Managed, designed and optimized the whole upstream chemical process system environment $300,000 eqv. /yr. and supervised 26 personnel as the Project/Plant manager.

WORK EXPERIENCE

Lead Design Engineer (Program Manager, Materials) (July 2010 – Continued)

General Electric, USA

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• Designed the first CMC airfoil/metal bucket of GE Energy as one of the prime group contributors (efficiency saving ~$76M).

• Designed on vibratory analysis of 6FA, 6B, 7FA & 9FB bucket systems, modal frequencies and shapes, modal cyclic symmetry (MCS), Campbell diagrams, nodal diameters, HCF/LCF analysis, fatigue failures, airfoils, blades and cooling systems.

• Led and co-ordinate the SEGR corrosion and erosion efforts from the beginning. Dictated the corrosion problems and their solutions through different analysis and processes by saving $ 7.5 M for the SEGR project.

• Led and co-ordinate the GE EBC synergy system of 4 cross-functional diverse EBC sub-groups ( min.16 experienced EBC personnel from Aviation, GRC or Energy) as Program Manager (Lean Six Sigma Green Belt certified), controlling ~ $ 90 M/Ann.

• Translated CTQ's to operating recipes and analytical targets at the design/manufacturing stages of New product implementation (NPI)/New product development (NPD) proactively saving ~ $16M.

• Owned the strategic planning, technology transfer/roadmap, scope of execution, process design, analysis and planning of Materials’ testing, optimized materials’ selection/choice for critical technological roadmap of Ceramic Matrix Composite(CMC) airfoils, shrouds and nozzles(~$7M/ann.).

• Designed the first CMC airfoil/metal bucket of GE Energy as one of the prime group contributors as per the Best Practice starting from initial design, new product development to manufacturing validations (efficiency saving ~$76M).

• Achieved the Green Belt certification (DMAIC and DFSS). Proficient in Failure mode & effects analysis (FMEA), Root cause analysis (RCA), Data interpretation, DOE, Fishbone tools etc.

• Led the whole project of designing, metal/materials’ selections, manufacturing/production and field-running of the EBC coated CMC substrates as the Project Manager and fructify the CTQs with sourcing, operations team and Supply chain co-ordination (~ more than $25 M/yr.). Analyzing wide variety of materials’ failures using field inspections, engineering analysis and experimental testings.

Applications Engineer (August 2000 - December 2002)

CFD Research Corporation, USA.

• Developed proficiency in operating, upgrading, and implementing CFD Research Corporation’s commercial simulation package CFD-ACE+.

• Performed successful applications development of the prevalent types of fuel cells including flow field design, liquid flow distribution, mechanical structural design and thermal optimizations.

• Co-developed customized simulation and modeling packages to support design efforts and improve the efficiency/power density of fuel cells and fuel processors/reformers, bipolar plates in the accelerated aging testing conditions.

• Searched constantly for potentially high-impact areas of research, new businesses and cost optimizations.

• Learned thoroughly to model, predict and control the simulation results of fluid flow, heat transfer and coupled multi-physics to design more efficient semiconductor processing.

• Designed, fabricated and improved the capabilities of the CFD-ACE+ package, (i.e. optimizer,

simulation-manager to satisfy the clients’ needs and win new business).

• Solved and troubleshot the real life problems of the industrial customers utilizing strong communication skills.

Senior Production Engineer (August 1991 - August 1998)

Oil and Natural Gas Corporation Limited (ONGC), India.

• Led the installation of a Total-Upstream-Crude-Process-System as Project/Installation Manager from pilot/startup/conception to construction/smooth operating conditions. The system encompassed heater treators, cooling towers, flocculators, dozing pumps, bath heaters, settling tanks, separators, dispatch pumps, other production surface facilities and unit operations.

• Established and performed scale up, corrosion problems, optimization and monitoring processes for high-pressure compressors/wells and reservoirs in the Insitu Combustion Processes (ICP) and Effluent Treatment Plant (ETP).

• Designed, supervised and troubleshot wet and dry injections of the Enhanced Oil Recovery (EOR, capital project) processes, fluid flow/phase system of heavy crude reservoir for continuous process improvements.

Das, page 3

• Managed, scaled-up and designed Hydrogen-Sulfide (H2S) Absorption Plant, as the primary decision-maker, saving ~ $50,000 eqv (Scientific benchmarking design study).

• Managed $300,000 eqv. /yr. and supervised 26 personnel in the Petroleum process plant environment as the Project/Plant manager.

Project Engineer

Hindustan Motors (P) Limited, India.

• Supervised Electroplating / Quality Control Division.

• Supervised Engine Assembly and completed con-current projects to maximize engine efficiency in a project management role.

Process Engineer

Phillips Carbon Black Limited, India.

• Conducted technology-based research and development(R & D) activities in day-to-day production of the carbon black plant including process design/control of the key chemical processes such as filtration, partial combustion, fluid phase transport, particle formation, dozing, mixing, granulating, drying, thermal operations and conveying.

• Proposed & designed well-conducted projects, scientific studies of optimized solutions for power requirements and process developments/controls of the whole chemical process/production plant.

EDUCATION

Ph.D, Metallurgical & Materials Engineering (GPA-3.9/4.0), The University of Alabama, July 2012, exp.

• Research Project: Experimental scope of novel materials for a better design of solid oxide fuel cell (SOFC) anodes and its validation via numerical simulations.

Research includes: Energy storage and sensor applications, hydrogen storage.

Materials characterization techniques include: XRD, EIS, XPS, SEM, TEM, FTIR etc.

Special emphasis given on advanced materials’ synthesis/production, thermal processing of advanced Ceramics and nano materials, sintering, their defect structures and solid state properties/solid state ionics.

MS, Materials Science & Engineering: (GPA-3.61/4.0), Georgia Institute of Technology, 2006

• Research project: Numerical steady/transient state modeling of the cathode of a solid oxide fuel cell (SOFC) system with the emphasis on defect chemistry and solid state transport.

MS, Chemical Engineering: (GPA-3.8/4.0), The University of Alabama in Huntsville, 2000

• Research project: A study of physico-chemical properties of slurries and their effect on imbibition in porous materials.

BS, Chemical Engineering: (GPA-3.5/4.0), Jadavpur University, Calcutta, India

• Research project: Stochastic analysis of the dynamics of a sieve shaker.

AWARDS (Patents) and ACCOLADES

• Dockets # 254373, # 254247, # 253921, # 259019, # 259018, # 259014, # 259015, # 259016, # 259017, # 258783, # 258782, # 256930, # 256891, #257013, #257015 patents applied.

SELECTED PUBLICATIONS and PRESENTATIONS

• Development of Anode Materials for Solid Oxide Fuel Cells-A Review, co-authored with R.G.Reddy, International Journal for Manufacturing Science and Production, vol. 10(1-2), pp. 27-41, 2009

• Computational Modeling of a Planar 3-D SOFC and the Effect of Materials Properties on the Anode Performance, co-authored with R.G.Reddy, International Journal for Manufacturing Science and Production, vol. 10(1-2), 1-10, 2009

• 3-D Modeling of Planar SOFCs and the Scope of Novel Materials for a Better Design of Anodes, co-authored with R.G.Reddy, Fuel Cell Technology and Business conference & exposition, Long Beach, CA, May 2008

• Recent Progress in Understanding Interfacial Reactions in SOFCs, co-authored with H. Abernathy, Y. Choi, S. Zha, Z. Cheng, J. Wang, E. Koep, R. Williams, J. Dong and M. Liu, 30th International Conference on Advanced Ceramics and Composites (American Ceramic Society), Cocoa Beach, FL, January 2006

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• Modeling of Micro-Impedance Measurements of Mixed-Conducting Electrodes for SOFCs, co-authored with M. Liu, Symposium for the Georgia Tech Strategic Energy Initiative, Atlanta, GA, 2006

• Microstructure and Electrochemical Properties of Cathode Materials for SOFCs Prepared via Pulsed Laser Deposition, co-authored with Erik Koep, Chunming Jin, Michael Haluska, Roger Narayan, Ken Sandhage, Robert Snyder and Meilin Liu, Journal of Applied Physics, 2006

• Modeling of Patterned Mixed-Conducting Electrodes and the importance of sheet resistance at small feature sizes, co-authored with David Mebane, Erik Koep and Meilin Liu, Solid State Ionics, 2006

• The Characteristic Thickness for a Dense La0.8Sr0.2MnO3 Electrode, co-authored with Erik Koep, Charles Compson, and Meilin Liu, Electrochemical and Solid-State Letters, 2005

• LSM Patterned Electrodes for Solid Oxide Fuel Cells, co-authored with Erik Koep, Charles Compson and Meilin Liu, October 2004, 206th Meeting of The Electrochemical Society, Inc., Honolulu, HI

• Three dimensional modeling of the medium size fuel cell stacks: thermal effects on the stack performance, co-authored with Vladimir Kudriavtsev (CFD Canada), Rob Delcore (Hydrogenics), 4th

International ASME/JSME/KSME Symposium on computational technology (CFD) for fluid/ thermal/chemical/ stress systems with industrial applications, August 2002, Vancouver, CANADA

• Tools and techniques for fuel cell performance simulation, co-authored with Alton Reich (CFDRC), Sandip Mazumder (CFDRC), Vernon Cole (CFDRC), 4th International ASME/JSME/KSME

Symposium on computational technology (CFD) for fluid/thermal/chemical/stress systems with industrial applications, August 2002, Vancouver, CANADA

• Modeling PEM Fuel Cell Stack Performance using computational fluid dynamics, co-authored with V. Kudriavtsev (CFD Canada), Canadian Section and Pacific Northwest Section of Electrochemical Society Conference (May 31, 2002 Vancouver, CANADA)

SOFTWARE SKILLS

• Operating System: Windows, UNIX, Linux

• Database: FoxBASE, Familiar with Sybase

• Language: FORTRAN, C and C++

• Proficient in ANSYS Classic and Workbench, NX Unigraphics, CFD-ACE+, Femlab, Fluent, ASPEN Plus, AutoCAD, MathCAD, Rhios, Daqview, Labview, Orchestrator, Microsoft Office, MS Project, ChemCAD, Primavera, Excel, PowerPoint, Word, Solidworks, Catia

PROFESSIONAL AFFILIATIONS AND AWARDS

• Graduate Ambassador, The University of Alabama, 2007-2009

• Fellow, Graduate Research/Creativity, The University of Alabama, 2007-2008

• PR Manager, student internship, SGA, The University of Alabama, 2007-2008

• Senator, SGA, Georgia Institute of Technology, 2003-2004

• Member, Sigma Xi scientific research society

• Member, Golden Key International Honor Society

• Member, American Ceramics Society (ACerS)

• Member, The Minerals, Metals & Materials Society (TMS)

• Member, Association for Iron and Steel Technology (AIST)

• Member, American Institute of Chemical Engineers (AICHE)

• Member, American Association for the Advancement of Science (AAAS)

• Member, The American Society of Mechanical Engineers (ASME)

• Core Member, Asian Pacific American Forum (APAF)

• Co-Chair, GE Leaders of tomorrow (GELOT)

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