Kalyan

QATASYS - schneider electric

This project is a C++-based Steam Turbine Performance Simulator that models the Rankine cycle and turbine stages (HP, IP, LP) to replicate power generation in a utility-scale setup. Boiler steam conditions are fed into the model, expanded through turbine stages, and exhausted into a condenser, while the program calculates real-time output such as shaft speed, generated MW, and thermal efficiency. A PID-based governor control loop is implemented to stabilize turbine speed under changing load conditions, ensuring smooth regulation of steam valves.

On top of the simulation, the system integrates a monitoring and protection layer. Synthetic sensor signals (pressure, flow, vibration, speed) are generated, filtered, and logged, enabling calculation of KPIs such as heat rate, stage efficiency, and vacuum margin. Safety mechanisms simulate overspeed trips, condenser faults, and sudden steam pressure drops, with automatic shutdown logic to prevent damage. An optimization engine explores control setpoints to improve turbine efficiency, with results exported in CSV/JSON for offline analysis. This creates a complete flow from simulation → control → monitoring → optimization, making the project relevant to both turbine operations and digital twin applications.

Roles & Responsibilities:

• Applied Object-Oriented Programming (OOP) to design turbine components as modular, reusable classes.
• Used STL containers, iterators, and algorithms for efficient state management, performance metrics, and logging.
• Implemented multithreading with synchronization primitives to run simulation, monitoring, and control tasks concurrently in real time.
• Followed SOLID principles and design patterns (Factory, Observer) to ensure clean, maintainable, and extensible architecture.
• Managed memory efficiently with RAII and smart pointers, ensuring stability in long-running simulations.
• Added exception handling and fault recovery mechanisms to replicate safe turbine shutdown and system robustness.
• Engineered file I/O pipelines for structured JSON/CSV logs, supporting offline analysis and easy integration with dashboards.
• Applied unit testing and modular design for validation of control algorithms and safety logic.
• Performed performance profiling and optimization to minimize latency in simulation loops and ensure near real-time responsiveness.