Domestic boiler test rigs

The test rigs needed to support development work on domestic methane- and hydrogen-fired boilers while remaining minimal, safe, operationally flexible and feasible to fabricate and assemble. The solution combined mechanical design with controls, instrumentation, procurement and close consultation with future users.

I led the project individually while collaborating with the engineers who would ultimately operate the equipment.

• Developed the mechanical rig architecture and detailed CAD design using Siemens NX.
• Designed and assembled the PLC control and data-acquisition system.
• Selected and procured manufacturing of custom parts, instrumentation, and PLC system components.
• Incorporated user feedback into the operating and maintenance layout.
• Applied the multidisciplinary experience to support and delegate work to subsequent interns.

The rigs were delivered successfully. The project led to a follow-on contract providing remote support and helped create a repeatable route for producing the remaining systems.