Hello, my name is
Kaarnesh Rajamurugan
Fuel Cell Systems & Process Engineer
Delivering decision-ready engineering evidence. Specializing in hydrogen fuel cell systems, oil & gas consulting, and process & test engineering. E.I.T based in Vancouver, BC.
Explore My WorkAbout Me
Everything around the goal is chaotic, but the goal itself isn't — I cut through the noise and deliver. What I bring is clarity: clear objectives, clear ownership, and clear learning loops.
I enjoy roles where complex systems need to be understood, validated, and improved—whether that's through modelling, testing, process design, failure analysis, or project execution. With a background in Chemical Engineering from UBC, I've been shaped by diverse project work across two complementary worlds: energy consulting in oil & gas, and research testing in hydrogen fuel-cell technology.
Early in my career at Advisian/Worley, I worked on process studies, modelling, PFD/P&ID development, and HAZOP-style reviews. At Ballard, I shifted into testing-focused roles, commissioning test rigs, resolving mechanical/electrical/control interactions, and running verification programs.
I'm open to interesting engineering projects across energy, industrial systems, R&D, sustainability, and emerging technologies. If the work has a real problem to solve and a structured environment for growth, I'm all in.
Technologies I work with:
- ▹Aspen HYSYS
- ▹MATLAB/Python
- ▹Fault Tree Analysis
- ▹DVP&R
- ▹DFMEA
- ▹PFD/P&ID Development
Experience
Fuel Cell System Test Engineer (EIT) @ Ballard Power Systems
May 2023 — Jul 2025 · 2 yrs 3 mos
Greater Vancouver, BC, Canada · On-site
Program Ownership & Delivery:
- ▹Owned end-to-end execution for compressor verification across three platforms → planned scope, sequencing, and debug priorities → recovered ~3 months of schedule slip without added resources.
- ▹Maintained alignment with supplier reviews, design gates, and freeze milestones under competing test demands.
Verification & Test Strategy:
- ▹Rebuilt verification strategy using DFMEA-driven requirements, expanded test coverage, and DVP&R pass/fail limits → shortened verification cycles by ~25% and reduced late-stage design rework.
Failure Analysis & Reliability Closure:
- ▹Led root-cause investigations for overvoltage events, CAN heartbeat losses, thermal drift, and sensor instability → applied Fault Tree Analysis → eliminated 10+ recurring failure modes.
- ▹Closed issues with corrective actions that held across repeat testing and operating conditions.
Test Infrastructure & Capability Build-Up:
- ▹Delivered <$1M in test-cell upgrades (bi-directional power, environmental chamber, instrumentation) → increased uptime from ~55% to ~90%.
- ▹Enabled stable, continuous testing across temperature and pressure envelopes.
Data Automation:
- ▹Built MATLAB/Python pipelines for high-volume time-series data → converted raw logs into decision-grade summaries → reduced analysis time from days to hours.
- ▹Standardized outputs for direct consumption by design, controls, and supplier teams.
Safety Leadership:
- ▹Chaired PHAs across design, pre-implementation, commissioning/startup, and operations → refreshed SOPs/PRCs and strengthened lab governance.
- ▹Served as elected JHSC co-chair → accountable for safety governance, corrective-action tracking, and regulator-facing readiness → sustained audit-ready compliance across lab and operations.
Communication:
- ▹Served as technical interface between suppliers, designers, controls SMEs, and internal stakeholders → translated test results and risk trade-offs into clear engineering decisions.
Featured Projects
Featured Project
Compressor Verification Program
Rebuilt the verification strategy for three compressor platforms at Ballard. Defined requirements as per DFMEA, established test coverage matrices, and set pass/fail limits following DVP&R methodology. This systematic approach helped shorten verification cycles by approximately 25% and improved iterative design rework processes.
- DFMEA
- DVP&R
- Test Engineering
- Data Analysis
Featured Project
Carbon Capture Studies
Supported carbon-capture and air-separation studies at Worley, developing ASPEN-based simulations and heat & mass balances during Select-phase evaluations. Researched global sulphur-recovery configurations and presented technology-selection findings to guide early-phase design decisions for client projects.
- ASPEN HYSYS
- Process Design
- Technical Research
- Heat & Mass Balance
Featured Project
Test Environment Upgrade
Led the capability upgrade of the test environment under $1M budget, implementing bi-directional power systems, thermal chambers, and advanced instrumentation. This initiative improved uptime from approximately 55% to 90%, enabling stable, continuous system testing across various temperature and pressure conditions.
- Systems Integration
- Instrumentation
- Thermal Testing
- Power Systems
Other Noteworthy Projects
Root Cause Analysis Framework
Used Fault Tree Analysis to isolate root causes of system issues including overvoltage, heartbeat losses, and sensor instability — eliminated 10+ recurring failures
- Fault Tree Analysis
- Debugging
Data Analysis Automation
Built MATLAB/Python workflows to process high-volume time-series data from fuel cell testing. Transformed raw logs into clear performance summaries, cutting analysis time from days to hours
- MATLAB
- Python
- Time-Series Analysis
Manufacturing BOM Optimization
Improved manufacturing BOM accuracy across three product lines at Ballard, contributing to an estimated ~$1M cost saving
- Process Improvement
- Lean
Skills
Engineering
Software & Tools
Leadership & Methods
Get In Touch
I'm currently open to new opportunities across energy, industrial systems, R&D, sustainability, and emerging technologies. If you have a challenging engineering problem, want to discuss sustainable solutions, or just want to connect — my inbox is always open.
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