About this Training Course
The reliability and durability of PEM electrolysers are critical to both performance and safety. PEM electrolyser failure analysis is essential for improving system reliability, durability, and safety. Designing reliable Proton Exchange Membrane (PEM) electrolysers requires more than technical proficiency; it demands a deep understanding of how and why systems fail, together with effective mitigation strategies, analytical methods, and preventive tools.
This training is designed to equip design engineers with the knowledge and practical skills needed to understand the key components and systems of PEM electrolysers, their operating principles, and the potential issues affecting system performance and reliability. Particular emphasis is placed on understanding the mechanisms, causes, and prevention of failures, including the degradation of PEM stack components such as membranes, catalysts, and related materials. Participants will gain insight into typical failure mechanisms, including corrosion effects, scaling, polymeric degradation, material compatibility issues, and chemically induced ageing under operational conditions. The course begins by grounding participants in the fundamentals of PEM electrolyser operation before progressing to the mechanisms that most often lead to degradation or breakdown.
Through a structured programme combining theory, case studies, and practical exercises that reflect real-world engineering challenges, participants will develop a strong understanding of common failure modes, diagnostic approaches, and design strategies that enhance system robustness. The course emphasises the interaction between materials, operating conditions, and system integration, enabling engineers to anticipate risks and implement effective preventive measures early in the design process.
By the end of the training, participants will understand the technical foundations of PEM electrolyser failures from both theoretical and practical perspectives. The course provides professionals with essential tools to support sustainable innovation and continuous improvement, enabling them to safely and effectively design, install, and operate PEM electrolyser systems.
By the end of this course, participants will be able to:
- Identify and classify common failure modes in PEM electrolysers.
- Comprehend the level of severity and risks each PEM failure mode pose to environment, health and safety.
- Understand the root causes of degradation in membranes, catalysts, and balance-of-plant components.
- Apply diagnostic tools and monitoring strategies to detect early signs of failure. This includes advanced in-situ electrochemical diagnostics such as Electrochemical Impedance Spectroscopy (EIS), cyclic voltammetry, and high-frequency resistance (HFR) mapping, as well as ex-situ laboratory characterisation techniques.
- Integrate design principles that improve durability, efficiency, and safety.
- Learn and practice the use of preventive and corrective tools such as FMEA, 5 Whys, Pareto chart, Fault Tree Analysis and Fishbone Diagrams (Ishikawa).
- Evaluate case studies and propose corrective actions for real-world scenarios.
- Design Engineers responsible for system architecture, component selection, and reliability-focused design of PEM electrolysers.
- R&D Engineers and Scientists engaging in materials development, performance optimisation, and innovation in hydrogen and electrolyser technologies.
- Process Engineers managing electrochemical processes, operating conditions, and system efficiency.
- Reliability and Asset Engineers focusing on failure analysis, durability improvement, and lifecycle management of electrolyser systems.
- Testing and Validation Engineers conducting performance testing, diagnostics, and durability assessments.
- Quality and Assurance Engineers ensuring compliance with safety, quality, and reliability standards.
- Operations and Maintenance Engineers supporting troubleshooting, monitoring, and preventive maintenance of electrolyser plants.
- Technical Specialists and Consultants providing expert support in hydrogen production, system integration, and risk mitigation.
- Product Development Engineers leading commercialisation, prototyping, and scale-up of PEM electrolyser technologies.
- System Integration Engineers managing balance-of-plant components and integration with renewable energy systems.
- Basic
- Intermediate
The training is delivered through a structured and interactive learning approach designed to maximise participant engagement and practical understanding. It combines instructor-led lectures with clearly defined learning outcomes, supported by hands-on exercises, real-world case studies, failure analysis, group discussions, and collaborative problem-solving activities. The programme includes both theoretical and practical components, achieved through brainstorming sessions and active learner participation in exercises and activities. The course follows an online modular structure delivered through a dedicated learning platform, with timed sections covering fundamentals, failure modes, diagnostics, and safety. Learning is reinforced through knowledge quizzes, interactive data-analysis tasks using operational datasets, and scenario-based case studies where participants diagnose failures and propose mitigation strategies. Assessments include automated scoring and instructor feedback. Participants will also have access to supplementary resources such as technical articles, analytical tools, and reference materials. A temporary login to the digital platform provides access to all course materials, enabling participants to engage using their personal laptops or tablets throughout the training.
Your expert instructor is a Chartered Mechanical Engineer with nearly 30 years of multidisciplinary experience in mechanical design, advanced engineering analysis, and hydrogen technologies. He is widely recognised for his expertise in PEM electrolyser systems, mechanical reliability, and failure analysis, as well as his ability to translate complex engineering concepts into practical knowledge for engineers and technical professionals. He is also an experienced instructor and mentor, having delivered technical training programmes on engineering design standards, hydrogen technologies, and regulatory frameworks to global engineering teams.
He currently supports hydrogen technology development and efficiency optimisation where he conducts research on improving PEM electrolysis performance. Previously, he worked with Quest Global (supporting Accelera by Cummins) as a technical reviewer and trainer for PEM electrolyser design, CE marking, PED certification, and failure analysis.
Throughout his career, he has led and contributed to major engineering innovation projects across the energy and industrial sectors. At Weatherford Ltd, he led multimillion-pound R&D programmes that resulted in patented open-hole packer technologies and innovative slip mechanisms used in advanced well completion systems. During his tenure at Freudenberg Oil & Gas Technologies, he developed and patented high-performance sealing solutions for high-pressure and high-temperature environments. At Petrowell Ltd, he helped develop the TerraForm packer system, which became one of the company’s flagship technologies.
In addition, he has contributed to engineering design optimisation and simulation projects with organisations such as TechnipFMC, Paradox Engineering Consultancy, and SPX Process Equipment, applying advanced FEA and CFD modelling to improve mechanical performance and reliability. He is a Chartered Engineer (CEng), a European Engineer (Eur Ing), and an inventor with six granted patents in mechanical engineering.
Unlock the potential of your workforce with customized in-house training programs designed specifically for the energy sector. Our tailored, in-house courses not only enhance employee skills and engagement but also offer significant cost savings by eliminating travel expenses. Invest in your team’s success and achieve specific outcomes aligned with your organization’s goals through our expert training solutions. Request for further information regarding our on-site or in-house training opportunities.
In our ongoing commitment to sustainability and environmental responsibility, we will no longer providing hard copy training materials. Instead, all training content and resources will be delivered in digital format. Inspired by the oil and energy industry’s best practices, we are leveraging on digital technologies to reduce waste, lower our carbon emissions, ensuring our training content is always up-to-date and accessible. Click here to learn more.
To further optimise your learning experience from our courses, we also offer individualized “One to One” coaching support for 2 hours post training. We can help improve your competence in your chosen area of interest, based on your learning needs and available hours. This is a great opportunity to improve your capability and confidence in a particular area of expertise. It will be delivered over a secure video conference call by one of our senior trainers. They will work with you to create a tailor-made coaching program that will help you achieve your goals faster.
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A: PEM electrolyser failure analysis studies why a system loses performance or stops working as expected. Engineers check membranes, catalysts, seals, separator plates, and operating data. They look for the root cause of damage. As a result, they can improve safety, reliability, and system life. In addition, this process helps teams stop the same problem from happening again.
A: Failure analysis helps engineers find small issues before they grow into major faults. For example, a weak membrane or worn seal can lower efficiency and raise safety risks. Because of this, early analysis supports better maintenance and better design choices. It also helps teams keep hydrogen production stable. Over time, that can reduce downtime and lower repair costs.
A: Common failure modes include membrane thinning, gas crossover, catalyst decay, corrosion, seal ageing, and sensor drift. In some cases, pumps, valves, and cooling units also fail. These issues may start with dirty water, heat, pressure changes, or poor material choice. Therefore, engineers study these patterns to reduce damage and improve system life. These are common findings in PEM electrolyser failures.
A: Membranes can fail because of chemical attack, repeated stress, heat, or water impurities. Likewise, catalysts can lose activity through dissolution, fouling, particle growth, or support corrosion. Harsh operating conditions often make these problems worse. So, engineers track these causes closely. That helps them improve durability, protect efficiency, and reduce performance loss.
A: Engineers use both online checks and lab tests. For instance, they may use impedance testing, gas crossover checks, resistance mapping, and trend analysis. They also review sensor data during operation. After disassembly, they may use microscopy and surface tests. Together, these tools help teams find faults early and confirm the true cause. These methods support earlier failure analysis of PEM electrolysers.
A: Both technologies face wear and damage, but the failure patterns differ. PEM systems often show issues linked to membranes, catalysts, and changing loads. In contrast, alkaline systems often focus more on liquid handling and separator behaviour. Because the risks differ, engineers also use different test methods and prevention steps for each system.
A: The field is moving toward smarter monitoring, better materials, and predictive maintenance. For example, new sensors can spot changes earlier. At the same time, digital tools can link operating data with fault patterns. Better membranes, catalysts, and corrosion-resistant parts may also extend system life. Therefore, failure analysis will remain important as hydrogen projects grow. This will improve PEM electrolyser failure analysis in large-scale hydrogen systems.
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