Position Title: System & Instrumentation Engineer – Electrolyser Stack & System

Location: Mumbai, India

Department: R&D;

Experience Required: 8-10 Years

About the Role

We are looking for an engineer with solid expertise in sensor technologies, instrumentation, and system design/development for electrolyser stacks and Balance of Plant (BoP) systems. The role will focus on end-to-end development of sensing architecture, system integration, automation, control strategies, and product-level engineering for advanced electrolyser systems.

This position is ideal for someone who can bridge hardware, sensors, controls, and complete system engineering while working closely with mechanical, electrical, software, and electrochemistry teams.

Key Responsibilities

1. Sensor Identification & Selection

Identify and select suitable sensors for stack and system applications such as:

o Temperature o Pressure / Differential Pressure o Flow o Level o Conductivity / pH o Humidity o Hydrogen Leak Detection o Voltage / Current o Insulation Monitoring

Evaluate sensors for harsh operating conditions including alkaline environment, water quality, vibration, temperature, and EMI/EMC noise.

Support vendor evaluation, make-vs-buy decisions, and technology benchmarking.

2. Stack-Level Sensor Integration

Develop sensor integration concepts within or around electrolyser stacks.

Implement solutions for

o Cell voltage monitoring o Temperature mapping o Pressure sensing o Leak detection o Diagnostic measurements

Recommend sensor mounting, sealing, cable routing, and protection strategies.

Ensure compatibility with stack materials and electrochemical operating conditions.

3.



System Design & Development

Design complete instrumentation architecture for electrolyser systems and BoP.

Develop P&IDs;, I/O lists, wiring architecture, signal maps, and control philosophy.

Support design of skid-mounted systems including pumps, valves, tanks, piping, gas-liquid separators, cooling systems, and safety systems.

Define communication protocols such as:

o Modbus o CAN o Ethernet/IP

Develop scalable designs for pilot, industrial, and multi-MW systems.

4. Controls & Automation Integration

Integrate sensors with PLC, DAQ, SCADA, HMI, and embedded systems.

Define signal interfaces such as 4–20 mA, 0–10 V, RTD, thermocouple, digital I/O, and serial communication.

Support control logic for startup, shutdown, pressure balancing, water management, alarms, and safety interlocks.

Work with software teams on dashboards, data logging, and predictive diagnostics.

5. Validation, Testing & Commissioning

Develop calibration, validation, and troubleshooting procedures.

Analyze signal quality, drift, response time, noise, and reliability.

Support lab test benches, FAT, SAT, commissioning, and field troubleshooting.

Drive root cause analysis for sensor/system failures.

6. Documentation & Cross-Functional Collaboration





Prepare engineering documents such as:

o Specifications o BOMs o Datasheets o SOPs o Test Reports o Validation Protocols

Coordinate with stack design, controls, software, procurement, manufacturing, and service teams.

Work with external vendors for custom instrumentation and automation solutions.

Required Qualifications :

Bachelor’s / Master’s degree in Instrumentation, Electrical, Electronics, Mechatronics, Mechanical, or related engineering field.

8-10 years of experience in sensors, industrial automation, system development, or product engineering.

Strong understanding of industrial sensing technologies and measurement principles.

Experience in PLC / SCADA / DAQ integration.

Knowledge of system design, wiring, controls, and industrial communication.

Hands-on debugging and troubleshooting skills.

Preferred Qualifications:

Experience in electrolyser, fuel cell, battery, hydrogen, or process systems.

Basic understanding of electrochemistry and stack operation.

Familiarity with LabVIEW, Python, MATLAB, NI DAQ, or similar tools.

Knowledge of hazardous area instrumentation and safety standards.

Experience in data logging, signal conditioning, and predictive maintenance.

Startup mindset with ability to work in a fast-paced R&D; environment.

Key Skills

Sensor Selection & Integration

Instrumentation Engineering

System Design & Development

PLC / SCADA / DAQ

Controls Engineering

Electrical Architecture

Validation & Testing

Troubleshooting

Technical Documentation

Vendor Development

Cross-functional Coordination

Problem Solving

📌 System & Instrumentation Engineer - Electrolyser (Mumbai)
🏢 InSolare Energy
📍 Mumbai