Bishnu P.

Experience

• Senior Manager – Experimental Mechanics Lab Corporate R&D Division, Bharat Heavy Electricals Limited (BHEL), Hyderabad, India, · Full-time Mar 2026 – Present 8 mos Hyderabad, Telangana, India Lead and execute multidisciplinary R&D and engineering validation programs involving mechanical design, analysis, integration, instrumentation, testing and validation of critical static and rotating equipment.
  Coordinate engineering activities across design, analysis, manufacturing, testing, quality, suppliers and field teams to deliver projects against technical requirements, milestones and customer commitments.
  
  Key Responsibilities
  • Coordinate mechanical engineering activities from design review and analysis through prototype development, testing, validation, and technical reporting.
  • Apply CAD and FEA tools to assess structural integrity, thermal behaviour, vibration characteristics, fatigue performance, and design reliability.
  • Work with design, manufacturing, metallurgy, quality, procurement, and customer teams to resolve design and product-performance issues.
  • Develop test methods, fixtures, instrumentation arrangements, and qualification procedures to verify product performance against technical requirements.
  • Support engineering decisions through analytical calculations, test data, failure investigation, and design–test correlation.
  • Coordinate indigenous component development and supplier technical interactions to improve cost effectiveness and reduce dependence on imported components.
  
  SELECTED PROJECT LEADERSHIP & ENGINEERING ACHIEVEMENTS:
  1. High-Speed Traction Motor – Thermal Design Validation | Vande Bharat Express
  • Led the engineering validation program for a high-speed traction motor rotating system through wireless telemetry-based rotor temperature measurement.
  • Developed the instrumentation methodology for measuring rotor temperatures at critical locations using K-type thermocouples and telemetry.
  • Coordinated activities involving Design, Testing, Manufacturing and customer-facing engineering teams.
  • Correlated experimental temperature measurements with FEA-based thermal predictions to support design validation.
  • Investigated instrumentation failure under rated-speed/rated-load conditions and implemented an improved thermocouple configuration.
  • Supported successful completion of the validation program and customer acceptance for Vande Bharat traction motor applications.
  Relevant capabilities: Product validation | Mechanical integration | Testing | RCA | Customer requirements | Cross-functional engineering
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  2. Advanced Ultra Supercritical (AUSC) Steam Turbine Rotor – High-Temperature Validation
  • Led engineering activities associated with the High Temperature Spin Test Research (HTSTR) program for advanced Alloy 617M turbine rotor development.
  • Developed test and validation methodologies for accelerated creep, low-cycle fatigue and high-temperature rotating conditions.
  • Coordinated mechanical instrumentation, rotor preparation, vibration measurement, temperature measurement and test-facility activities.
  • Supported engineering investigations following abnormal vibration/test events through RCA and corrective-action development.
  • Coordinated with manufacturing and external technical organizations for rotor modification, balancing and test readiness.
  • Developed engineering documentation and technical reports for project reviews and validation activities.
  • Contributed to an advanced test capability intended to support validation of turbine rotor design life under accelerated conditions.
  Relevant capabilities: Rotating machinery | Project execution | RCA | Test engineering | Cross-functional coordination | High-temperature engineering
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  3. API 8C Hoisting Equipment – Mechanical Design Verification & Certification
  • Led mechanical verification activities for 1500T-class travelling block and deadline anchor equipment.
  • Developed FEA-based stress/strain assessment and experimental proof-load validation methodology.
  • Planned instrumentation using strain gauges, load measurement and data acquisition systems.
  • Coordinated design, manufacturing and testing activities to demonstrate compliance with API 8C requirements.
  • Prepared technical documentation and validation reports supporting certification and customer requirements.
  Relevant capabilities: Mechanical product engineering | Design verification | Standards compliance | Testing | Manufacturing coordination
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  4. Indigenous Development of 800 MW Turbo-Generator Aluminium Alloy Blowers
  • Directed mechanical development and validation of high-speed blower assemblies as an import-substitution initiative.
  • Coordinated design, casting/manufacturing, assembly and validation activities.
  • Supported design optimization based on structural, thermal and operational requirements.
  • Achieved approximately 85% cost reduction through indigenous development and replacement of imported blower units.
  • Coordinated technical resolution of manufacturing and performance issues during product realization.
  Relevant capabilities: Product development | Manufacturing support | Cost reduction | Supplier coordination | Design optimization
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  5. Traction Motor Ventilation Fan – Product Development & Validation
  • Led development of rotor-mounted ventilation fan systems from concept through prototype testing and validation.
  • Developed a dedicated endurance test rig for rotational and shock-load testing up to 3000 rpm.
  • Correlated experimental results with FEA predictions to validate structural performance.
  • Supported field validation and reliability assessment of the developed system.
  • Coordinated design, fabrication, testing and engineering evaluation activities.
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  6. LP Turbine Blade – Vibration, Modal & Resonance Analysis
  • Conducted experimental vibration and modal characterization of 660 MW steam-turbine LP blades.
  • Performed FEA correlation and developed Campbell and interference diagrams.
  • Identified resonance conditions and supported engineering recommendations for design validation.
  • Achieved correlation between experimental and analytical results within approximately 5–8%.
  • Prepared technical analysis and engineering reports for design and project review.
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  7. Prototype Air Pollution Control Tower – Engineering & System Integration
  • Led engineering realization of an 80,000 m³/hr air-pollution-control tower.
  • Coordinated mechanical design, structural analysis, CFD-based optimization, filtration-system integration, fabrication and commissioning.
  • Worked across multiple engineering disciplines to transition the concept into a functioning prototype.
  • Supported installation, commissioning and resolution of technical issues during implementation.
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  8. Thrust Pad Load Cell Development – Product Engineering
  • Developed FEA-optimized thrust-pad load-cell solutions for monitoring load distribution in hydroelectric applications.
  • Integrated mechanical design, instrumentation, calibration and validation activities.
  • Supported field deployment of the developed measurement system.
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  PROJECT MANAGEMENT & LEADERSHIP
  • Project planning and engineering milestone management
  • Multidisciplinary engineering team coordination
  • Design–Manufacturing–Testing interface management
  • Technical resource and workload planning
  • Risk and issue identification / closure
  • Root-cause investigation and corrective actions
  • Supplier and vendor technical coordination
  • Customer/stakeholder technical presentations
  • Engineering review and project-status reporting
  • Test planning and validation governance
  • Cost-reduction and indigenous-development initiatives
  • Engineering process improvement and data automation
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  ENGINEERING & DIGITAL TOOLS
  CAD / Product Engineering
  • Siemens UG-NX
  • SolidWorks
  • IDEAS
  • 3D modelling and assembly development
  • GD&T and tolerance considerations
  • Mechanical integration
  CAE / Simulation
  • ANSYS Workbench / APDL
  • ABAQUS
  • HyperMesh
  • Structural FEA
  • Thermal analysis
  • Modal analysis
  • Fatigue analysis
  • Vibration analysis
  • CFD principles
  Testing & Instrumentation
  • Strain gauges
  • Accelerometers
  • Thermocouples
  • Load cells
  • Telemetry systems
  • DAQ systems
  • Non-contact measurement
  • Rotor temperature measurement
  • Vibration measurement
  • Custom test-rig development
  Engineering / Project Tools
  • MS Project
  • Microsoft Excel
  • Excel VBA / test-data automation
  • MATLAB
  • Microsoft PowerPoint
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  STANDARDS & ENGINEERING METHODS
  • API 8C
  • IEC
  • RDSO
  • ASTM
  • IS standards
  • Design verification and validation
  • Root Cause Analysis
  • FMEA / FMECA
  • Engineering test methodology
  • Experimental–FEA correlation