Portable Fuel Cell Test System for Hydrogen Engine Validation

Custom mobile test stand with integrated utilities, instrumentation, and controls

Capabilities Demonstrated

Fuel cell system integration
Custom mechanical design and mobile skid fabrication
Instrumentation and automation engineering
Control panel wiring and field device commissioning
Client software integration and FAT coordination

Challenge

A clean energy manufacturer developing next-generation hydrogen-powered engines needed to expand its testing infrastructure to validate performance across multiple product lines. The systems had to simulate real-world utility load conditions, integrate with facility gases and chilled water, and be portable enough for use across different lab environments.

The client also required full instrumentation, PLC-based automation, and seamless integration with proprietary software. This called for a highly flexible test platform with precision engineering, rapid build cycles, and the ability to support future scaling.

Approach

Re:Build Optimation served as the turnkey partner, leading all phases from design through fabrication and testing. The engagement began with close collaboration between engineering teams to define system requirements and interface compatibility.

Key workstreams included:

Designing utility integration for hydrogen, nitrogen, air, deionized water, and chilled water
Fabricating a high-strength mobile test cart to support lab-to-lab portability
Installing and pressure-testing fluid systems and safety components
Wiring and commissioning field instrumentation for full sensor and actuator control
Validating proprietary client software on a PLC control system to enable seamless functionality prior to shipment

Solution

Re:Build Optimation delivered a fully integrated, mobile fuel cell test platform designed for repeatable, flexible testing in a variety of lab environments. The solution featured:

Utility Integration: All necessary facility gases and liquids tied into the system via reinforced connectors
Mobility: Compact cart with locking casters, allowing movement between test stations or labs
Instrumentation and Controls: Fully wired sensors, actuators, valves, and field devices connected to a custom control panel
Software Compatibility: Client’s proprietary software was installed and tested on the PLC system to ensure data acquisition and test automation
FAT & Delivery: System was fully tested, disassembled, and shipped for site reassembly and final use

Results

The system enabled precise, repeatable testing of hydrogen-powered engines and provided the flexibility to scale across future product lines. With full integration of utilities, controls, and proprietary software, the project was delivered on time and met all technical performance requirements. The success of this initial platform led to continued collaboration and the development of additional test systems to support the client’s growing clean energy portfolio.

Benefits & Impact

Validated Hydrogen Fuel Cell Engines: Provided the testing infrastructure needed to verify system performance under simulated load
Increased Test Coverage: Enabled efficient, repeatable testing across multiple labs
Accelerated Development: Reduced setup time and allowed faster iterations for new product lines
Software Integration: Ensured seamless operation using the client’s proprietary control and data collection tools
Scalable Design: Platform serves as a foundation for future variants and higher-capacity test systems

System Overview

System Type: Portable fuel cell test platform
Function: Simulates utility load conditions to validate hydrogen-powered fuel cells
Key Features: Mobile test cart, PLC control panel, instrumentation suite, facility gas and water utility integration
Deployment: Built, tested, and shipped to client facility for hydrogen engine validation
Industries Served: Clean energy, hydrogen technology, industrial vehicles, transportation

Ready to Partner?

Let’s talk about your unique challenges and how Re:Build Optimation can help you.

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Capabilities Demonstrated

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The Challenge

Ready to Partner?

Let’s talk about your unique challenges and how Re:Build Optimation can help you.