Special instrumentation for turbomachinery and high-performance applications

Elettromar designs, installs and maintains special instrumentation systems for high-performance applications requiring precision, customization and proven field expertise.

From sensor integration to data validation, we support customers in transforming complex operating conditions into reliable and measurable performance.

Advanced expertise for high value instrumentation projects

Over the years, Elettromar has developed specialized expertise in instrumentation for critical components and demanding operating environments.

Our background in turbomachinery applications has enabled us to expand our capabilities into additional sectors including aerospace, automotive, racing, defence and research applications, where reliability, precision and repeatability are essential.

We operate on both static and rotating components, supporting testing, validation and performance monitoring activities through customized instrumentation solutions.

Turbomachinery gauging and sensor installation

Elettromar carries out turbomachinery gauging and installation of sensors on turbomachinery components such as gas turbines, steam turbines, centrifugal compressors, axial compressors and general mechanical parts. 

Our team manages strain gauges installation on turbomachinery, designing and installing custom strain gauges and sensor systems according to customer requirements.

We install and integrate a wide range of sensing technologies, adapting each solution to the mechanical, thermal and operational constraints of the component under test.

  • Temperature sensors
  • Pressure sensors, dynamic and static
  • Structural load and strain, structural health monitoring sensors
  • Vibration sensors
  • Acoustic sensors
  • Proximity Sensors
  • Laser Sensors

We also integrate advanced technologies such as telemetry systems, Bently Nevada and Kulite instrumentation, supporting reliable data acquisition and validation on both static and rotating components.

Special instrumentation techniques for critical components

Over the years, Elettromar has developed dedicated application procedures to ensure accurate sensor installation, reliable signal transmission and component validation in high temperature, corrosive, wet or mechanically complex environments.

Elettromar performs sensor splicing on flexible and rigid metal cables of different sizes, from very small diameters to common industrial cable sections, ensuring reliable signal continuity.

We develop splicing solutions with insulating resins for high temperature, corrosive and wet environments, protecting connections where standard methods are not enough.

Sensors can be applied directly to the component through tack welding machine processes and Nichrome strip, a technique commonly used for thermocouple installation.

This technique allows thermocouples to be immersed into the material. A hollow is created, the sensor is positioned and the surface is restored through filler wire and tack welding.

Elettromar installs and connects sensors on rotating components through Telemetry systems, allowing physical parameters to be monitored during normal turbomachinery operation.

Elettromar studies, designs and builds demagnetiser systems for compressor impellers and compressor or turbine blades, supporting specific testing and component preparation needs.

Wind Tunnel Laboratory and Performance Validation

To complement its special instrumentation capabilities, Elettromar operates a dedicated Wind Tunnel Laboratory where advanced fluid dynamic testing activities are performed through dedicated flow-testing lines designed for the characterization and validation of industrial and aero-derivative components.

Testing activities are carried out on combustion chambers, burners, nozzles, turbine blades, probes, and other critical components, ensuring high standards of accuracy, reliability, and performance verification.

In addition to fluid dynamic testing, the laboratory provides mechanical assembly services, component preparation, and installation of measurement instrumentation required for test execution.

Available Test Facilities

The Wind Tunnel Laboratory supports a wide range of testing and validation activities designed to characterize the performance of critical components under controlled operating conditions.

Available testing capabilities include:

• Calibration and validation of custom-designed aerodynamic probes developed according to customer specifications.
• Flow rate measurement and characterization of combustion chambers.

The Cincinnati test bench is dedicated to low-flow measurements on cooling circuits and fuel lines of machine components. Testing is performed using high-precision instrumentation, such as sonic nozzles, ensuring accurate and repeatable results.

The Air Flow Line is designed for medium-flow measurements using high-accuracy instrumentation, including Coriolis flow meters, enabling detailed performance analysis and verification of tested components.

The Compressor Line is designed for testing applications involving high flow rates and high-pressure conditions. Measurements are carried out using precision instruments, such as Coriolis flow meters, ensuring accurate monitoring and control of operating parameters throughout the testing process.

The laboratory performs leak tests up to 200 bar using nitrogen or helium, allowing the verification of component integrity and sealing performance under demanding operating conditions.

Testing activities can be combined with dedicated instrumentation, mechanical preparation, assembly services and data validation support, providing customers with a complete testing and engineering solution.

From customer requirements to validated data

Every project starts from a close technical dialogue with the customer. 

Elettromar supports the entire development process, including:

  • Engineering and requirements analysis
  • Concept development
  • 3D modelling
  • Production process development
  • Quality control
  • Sensors installation
  • Test assistance
  • Data validation and post-processing

This method is supported by structured project management and by in house software development, allowing Elettromar to create proprietary tools tailored to specific customer needs.

Our approach combines engineering flexibility, technical precision and operational reliability. This is why special instrumentation has become a strategic area for Elettromar: a field where long experience, micro weldings, Micro TIG, hot micro junctions and customized sensor applications become concrete value for the customer.

Project management

Need more information or project references?

Contact Elettromar to learn more about our special instrumentation expertise, available technologies and case histories developed for high technology applications.

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