Project Experience
Large-Scale Electrolyzer Commissioning
25 MW Hydrogen Electrolyzer in Florida, USA
Role: Lead Commissioning Engineer
Project Scope
Led commissioning activities for a large-scale hydrogen production and purification systems, managing a team of eight commissioning engineers through system testing, troubleshooting, operational readiness, start-up execution, and Site Acceptance Testing.
Responsibilities & Achievements
- Led field commissioning activities from installation completion through operational handover
- Executed system testing, troubleshooting, and functional validation activities
- Coordinated commissioning activities across mechanical, electrical, instrumentation, controls, EPC, and customer teams
- Supported operational readiness activities leading to first hydrogen production
- Performed functional safety validation and verification activities
- Led testing and debugging of a first-of-its-kind hydrogen purification system
Key Challenges
- Coordinating activities between EPC contractors, customer commissioning teams, equipment suppliers, and end operators
- Troubleshooting complex multi-disciplinary systems during first start-up
- Commissioning and validating a first-of-its-kind zero-loss hydrogen purification system
- Managing significant supplier equipment delays, communicating schedule impacts, and coordinating recovery plans with project stakeholders
- Resolving technical issues while maintaining project schedule and operational readiness
10 MW Electrolyzer Commissioning
Containerized Hydrogen Production System in Vienna, Austria
Role: Lead Commissioning Engineer
Project Scope
Led on-site commissioning activities for a containerized hydrogen production system installed within an existing industrial refinery environment. Coordinated commissioning execution, system validation, and operational readiness activities with a small field team and multiple project stakeholders.
Responsibilities & Achievements
- Executed commissioning activities through initial start-up, including equipment testing, troubleshooting, and system validation activities
- Supported system readiness activities leading to hydrogen production
- Performed instrumentation verification, including device configuration updates via the HART communication protocol
- Coordinated commissioning activities between the customer, EPC, equipment suppliers, and site teams
- Delivered operator training in German
Key Challenges
- Managing commissioning activities following significant project delays and rebuilding customer confidence
- Coordinating multiple stakeholders during a high-expectation start-up environment
- Integrating containerized equipment into an operating industrial facility
- Completing functional safety testing and verification of all Safety Instrumented Functions (SIFs) before production release
- Resolving technical issues while maintaining safe and reliable operation
Rectifier Harmonic Case Study
Industrial Hydrogen System | Power Quality and Equipment Reliability
Role: Field Service Engineer
Problem Overview
Investigated a rectifier failure that interrupted power delivery to a hydrogen production system. The failure occurred within an air-cooled transformer and SCR rectification system, requiring troubleshooting to identify the underlying cause and prevent recurrence.
Investigation & Resolution
- Performed site investigation of the rectifier and harmonic filter system following equipment failure
- Evaluated operating conditions, electrical loading, and power quality impacts
- Identified harmonic distortion introduced by a large compressor load connected to the 4.16 kV bus
- Determined that continuous operation of the harmonic filter was causing excessive stress on filter capacitors
- Supported corrective actions to address the root cause and restore reliable system operation
Key Challenges
- Diagnosing a system-level failure involving power electronics, harmonic distortion, and equipment interaction
- Coordinating troubleshooting activities in a live industrial environment while maintaining safe work practices
- Working within a union environment and incorporating required Lockout/Tagout (LOTO) procedures and additional scheduling considerations
- Restoring equipment reliability while maintaining customer confidence through safe and disciplined field execution