Christopher Rafferty

Experience

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  Argos

  Sept 2009 - Jun 2014

  Customer Advisor

  • Gained good experience of working within a team where I developed my teamwork and leadership skills• Roles required communication and negotiation with customers in order to meet the stores sales targets• Learned to deal with conflicts in the workplace

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  Rolls-Royce

  Jun 2014 - Dec 2014

  Intern - CFD Methods

  • I investigated a wide range of Computational Fluid Dynamics (CFD) modelling methods for the analysis of high-pressure turbine internal cooling in order to define best practise for future analysis. This involved benchmarking one of Rolls-Royce's industrial CFD codes and commercial CFD codes such as Fluent and STAR-CCM+ against experimental data. Different meshing techniques were implemented and the use of more advanced turbulence modelling was explored during this investigation.• I presented my work at the 2014 Automatic Design and Optimisation Seminar (ADOS), a CFD conference attended by a wide range of Rolls-Royce engineers and academics from the University of Cambridge. I used this opportunity to further develop my presentation and public speaking skills.• I demonstrated strong analytical skills throughout my project. Development of the CFD meshes of the extremely complex turbine cooling channels required a combination of logical thinking and creativity while the fluid flow analysis required problem-solving with deep mathematical understanding. Interaction between different departments in different countries required strong communication skills in order to arrange test cases and gather the relevant data for my project. I have also become highly skilled with a wide range of CFD software that was essential for my project. Show less

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  Rolls-Royce

  Sept 2015 - Jan 2021

  • I ran a series of engine emissions certification tests required to certify use of a low emissions modification I developed in the rig test program on the Trent XWB-97. I successfully certified the engine with over a 50% reduction in particulate emissions by writing certification reports to EASA• I secured a patent and have another pending on an innovative nozzle design concept that successfully reduced particulate emissions by up to a half on both Trent XWB-97 and Trent 1000 TEN engine emissions tests• I led a team of CFD analysts working globally to develop a reduced NOx combustor design. This had several technical challenges, such as having to meet restrictive requirements on allowable turbine temperature changes and engine altitude relight performance. Coordinating the different teams took good communication through running regular team meetings• I used statistical experimental analysis via Minitab to significantly upgrade our test capability in our full engine core rig in Cologne. I generated evidence on test to support the elimination of an old embedded method of particulate emissions measurement from the testing process and replaced it with the new system I constructed. This halved the time-on-test required at this facility, delivering cost benefits of ~2 million euros per year while considerably improving the data quality• I was nominated for the Sir Henry Royce Engineering award for my work in this role Show less • In-service issues were identified on the Trent XWB-97 and 1000 TEN engines where our combustor designs were causing high levels of particulate matter emissions. Rolls-Royce had limited understanding of what design factors drove the particulate emissions at the time, as combustion testing was prohibitively expensive and CFD modelling of particulate emissions was unreliable. My role was to understand and address these in-service issues• I designed a rich burn test combustor for testing of fuel spray nozzles in a low-cost, readily available combustion rig on-site in Derby. I then constructed an emissions measurement, sampling and exhaust system that required understanding of the flows in the rig, rating valves and lines for different flow temperatures, pressures, water content and soot contamination levels. I repaired several old facility systems and wrote procedures for training new operators on how to operate the rig safely• I ran a commissioning test campaign leading a team of graduates and research assistants. I demonstrated that the low-cost on-site rig ranked nozzle particulate performance in-line with engine test results. This was a significant breakthrough, it allowed fast testing turnaround times to react to the service issues while costing around 200 times less than an equivalent full engine core test• Once commissioned I ran hundreds of combustion tests on the rig to develop new understanding of the sensitivity of particulate emissions to a range of combustor design factors. I presented my research and new nozzle design proposals at several global conferences• I have developed my leadership skills during this role by supervising a team of several graduates and research assistants. Managing the testing required project planning of rig availability, emissions equipment operators, hardware delivery and project decision deadlines to obtain the required combustor performance understanding• I was nominated for the Sir Henry Royce R&T award for this work Show less • Working as a Producibility Lead in Compressor Components involved communication with engineers across Manufacturing, Design, Purchasing and our Suppliers. I altered engineering drawings of the Fan Blade Annulus Fillers across the Trent Fleet making them easier to manufacture. As a result, the Right First Time (RFT) manufacturing percentage increased by ~20% across the Trent Fleet. This also avoided an aircraft from being grounded due to lack of spare parts, avoiding large fines for the company. Show less • I took on several projects in this role, such as carrying out an engine emissions test on the XWB-84 for emissions certification with EASA, performing plume dispersion modelling to model the unburned kerosene emissions of a combustion rig, creating a flow tool to future proof Rolls-Royce's emissions measurement capability and starting the design process of a reduced dump-loss combustor.• I developed my experience in experimental analysis by preparing and running an XWB-84 engine emissions test and analysing the data produced by the test to write a certification report to EASA. I also attended engine tests on the 1000 TEN, 900 and XWB-97 engines. • I learned the processes involved in producing tender documentation while making a transaction with the MET Office for the plume dispersion modelling. • I presented to several primary schools on behalf of Rolls-Royce with Derby City Football Club. The objective of my presentations was to spark their interest in STEM activities while breaking down the gender stereotypes associated with engineering. I showed a wide range of different roles utilising STEM throughout RR and DCFC to show the variety of places that studying STEM later in life can take them.• I was nominated for the Steve Gegg award for my work on the plume dispersion modelling for the new combustion facility. Show less • My project was to develop an optimised inspection process reducing the cost of manufacturing the Trent XWB-84 HPIP structure and to redesign the IGB Sump Adaptor to combat a wear issue for the Trent 1000 TEN and Trent 7000 turbofans.• I developed my knowledge of engineering drawings and manufacturing processes. I gained experience in design by working through the design process and designing an engine component that will be implemented in the Trent 1000 TEN and Trent 7000. I developed a new optimised inspection process that offers Rolls-Royce a large cost-reduction on every Trent XWB-84 HPIP structure manufactured.• I demonstrated a clear logical approach to problem solving during the design of the IGB Sump Adaptor and used a creative thought process to generate design concepts to solve a complex design challenge. I gained experience writing technical specifications.• I broadened my engineering knowledge by attending several IMechE lectures at Derby University to learn about engineering outside of the mechanical/aerospace sector. I became a STEM ambassador to promote engineering to young engineers and started a STEM program that collaborates with Derby City Football Club to teach school students about the wide range of engineering applications. Show less

  • Aerothermal Engineer - Combustion (Trent XWB-97 Project)

    Dec 2019 - Jan 2021

  • Aerothermal Engineer - Combustion (Rich Burn Improvement Program)

    Feb 2017 - Dec 2019

  • Technical Lead - Fuel Spray Nozzle Design Project

    Oct 2016 - Feb 2017

  • Producibility Lead - Compressors

    Jun 2016 - Oct 2016

  • Aerothermal Engineer - Combustion

    Jan 2016 - May 2016

  • Design Engineer - Structures & Transmissions

    Sept 2015 - Jan 2016
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  Rolls-Royce

  May 2021 - now

  Assistant Resident Engineer (Mechanical)