Engine Testbed Fuel System
A full electrical and controls installation to expand and future-proof Red Bull’s engine test bed fuel systems.
STEP ONE
What Was the Brief?
Red Bull Powertrains required a significant upgrade and extension of their existing fuel system to serve additional engine test beds in their new powertrains facility. The project called for the close collaboration of several key partners:
TSG, the main contractor, brought extensive expertise in fuel system mechanical design and served as the main client interface. TSG was responsible for the mechanical aspects (including pipework) and ensured the project’s overall coordination.
AVL, renowned for their advanced modular engine test cells, supplied and shipped these complex systems from Austria. Their solutions form a critical part of Red Bull’s testing infrastructure.
Our team worked seamlessly alongside TSG and AVL, coordinating efforts to integrate the new fuel system with AVL’s modular test cells. This teamwork required careful planning to align mechanical and electrical systems and deliver user-centric solutions that met Red Bull’s operational needs.
The project’s success relied on excellent communication, shared technical standards, and a unified approach to safety, control integration, and future maintenance.
STEP TWO
What Did Meson Do?
Extended the fuel system to feed additional test beds, increasing capacity and efficiency.
Collaborated with partners AVL (supplier of modular test cells) and TSG (mechanical contractor) to deliver a seamless integration of mechanical and electrical systems.
Upgraded the entire test cell system, implementing new Siemens unified HMIs and a more advanced control panel based on a 1500 PLC, while integrating legacy systems for unified management.
Carried out full safety integration, including emergency stop and fire alarm connectivity.
Designed user-friendly HMI sequences to simplify operations for engineers.
Provided on-site installation, factory acceptance testing, commissioning, and comprehensive training for end-users.
Maintained flexibility to resolve on-site challenges rapidly, such as adapting installations to unforeseen changes without delay.
STEP THREE
What Was the Result?
Successful installation and commissioning of the expanded fuel system, delivering increased functionality and reliability.
Enhanced operator experience with improved system visibility and control across all test cells.
A forward-compatible control platform, ready for future automation and data integration developments.
Positive client feedback, particularly regarding the collaborative approach, neatness of engineering solutions, and willingness to educate and coordinate with other trades.
Ongoing support through annual service contracts, including ATEX inspections, electrical testing, and firmware updates.
Our approach to quality, transparency, and adaptability was recognised and appreciated by the client’s engineering team. By providing thoughtful, well-coordinated solutions and responding flexibly to challenges, we delivered a system that not only meets technical requirements but also stands out for its professional execution and ease of future maintenance.
Our relationship with the client extends beyond project delivery. We continue to provide annual service and maintenance, including ATEX inspections, electrical testing, and firmware/PLC updates. This ongoing support ensures system compliance, reliability, and performance well into the future.
Speak to our team today.
0113 286 4300
enquiries@mesonelectrical.com
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