Mechanical Testing Engineer

JOB DESCRIPTION

Position

Fuel Cell Systems Engineer

Division

Energy Inception Division (EID)

Location

Chinchwad, Pune

Number of Positions

1

Experience Range

5 - 6 years

Function

Engineering

Reporting to

Lead Fuel Cell Systems Engineer

Preferred Industry

Fuel Cell, Battery, Electrolyzer, Hydrogen Technologies, Advanced Materials, Aerospace & Defence Programs

PURPOSE OF THE ROLE

To execute field installation, commissioning, testing, troubleshooting and customer acceptance of fuel cell systems, stacks and hydrogen-based power generation equipment while ensuring safe operation, technical compliance and high customer satisfaction.

The role acts as the technical bridge between

Engineering, Production, Quality and the Customer during commissioning and validation.

KEY RESPONSIBILITIES

1. Site Preparation

Review approved GA drawings.

Review P&IDs.

Verify utility readiness.

Verify site safety compliance.

Check hydrogen infrastructure readiness.

Verify electrical readiness.

Prepare commissioning checklist.

Review FAT documentation before dispatch.

1. Installation Supervision

Supervise unloading.

Verify equipment integrity.

Coordinate installation.

Ensure equipment alignment.

Verify piping installation.

Verify electrical termination.

Check instrumentation installation.

Ensure installation follows approved drawings.

1. Commissioning

Execute complete commissioning of:

Fuel Cell Stack

Hydrogen Supply System

Cooling System

Air Supply System

Water Management System

Electrical System

PLC/SCADA

Safety PLC

Hydrogen Detection System

Emergency Shutdown (ESD)

Activities include:

Leak testing

Pressure testing

Purging

Sensor calibration

Instrument validation

Functional testing

Interlock verification

Safety validation

1. Performance Testing

Conduct and document:

Polarization curve testing

Stack performance validation

Load testing

Efficiency measurement

Hydrogen consumption measurement

Water production measurement

Heat recovery validation

Dynamic load testing

Endurance testing

Grid synchronization testing (where applicable)

1. Customer Acceptance Testing

Lead Site Acceptance Test (SAT):

Execute approved SAT protocol

Demonstrate guaranteed performance

Record operating parameters

Resolve punch points

Obtain customer acceptance

Prepare SAT report

Support warranty handover

1. Troubleshooting

Diagnose and resolve:

Fuel cell performance degradation

Hydrogen system faults

Cooling system issues

Air supply issues

Power electronics alarms

PLC logic issues

Instrument failures

Sensor deviations

Communication failures

Perform Root Cause Analysis (RCA) and recommend corrective actions.

1. Safety

Ensure compliance with:

Hydrogen safety procedures

Lock Out Tag Out (LOTO)

Permit to Work (PTW)

Confined Space requirements

Electrical safety

Hot work requirements

Hazardous Area requirements

Conduct:

Toolbox talks

Job Safety Analysis (JSA)

Pre-start safety reviews

1. Documentation

Prepare:

Commissioning reports

Daily site reports

SAT reports

Test logs

Calibration records

NCR reports

Punch lists

Customer sign-off documents

Warranty documentation

1. Customer Support

Provide:

Operator training

Maintenance training

First-level technical support

Warranty support

Site troubleshooting

Annual maintenance support

Develop strong customer relationships through professional execution and timely issue resolution.

1. Continuous Improvement

Capture field learnings.

Recommend design improvements.

Support FMEA updates.

Improve commissioning procedures.

Standardize test protocols.

Reduce commissioning cycle time.

Enhance reliability and maintainability.

Qualifications

• · Essential Qualification : Bachelor’s Degree in Mechanical / Electrical / Chemical

• CRITICAL COMPETENCIES OF THE JOB

• Fuel Cell

• · Fuel Cell fundamentals

• · Stack operation

• · Electrochemistry

• · Performance diagnostics

• Hydrogen

• · Hydrogen handling

• · Hydrogen safety

• · Pressure systems

• · Gas purification

• · Leak testing

• Instrumentation

• · Pressure transmitters

• · Flow meters

• · Temperature sensors

• · Hydrogen detectors

• · Control valves

• Electrical

• · LV systems

• · MCC

• · PLC

• · SCADA

• · VFDs

• · UPS

• · Grid synchronization

• Software

• · MS Office

• · AutoCAD

• · PLC diagnostics

• · SCADA

• BEHAVIORAL COMPETENCIES

• · Strong analytical and troubleshooting skills.

• · Customer-focused mindset.

• · Excellent communication and presentation skills.

• · Ability to work independently at remote customer sites.

• · Strong planning and documentation discipline.

• · High safety awareness.

• · Team collaboration across engineering, production, quality, and service functions.

• · Willingness to travel extensively.