How Purna Delivered a Fully Integrated Design for a Complex Test Environment
Working within an existing plant meant, Purna had to design solutions that respected the old while meeting the demands of modern turbine testing. The system had to manage high pressure flow conditions, allow safe operational flexibility and support continuous data driven performance evaluation of turbines.
This project involved transforming an established plant into a highly reliable and automated turbine testing environment. To achieve this, several critical components had to be introduced including customised test gigs, a dedicated boiler system, precise instrumentation and specialised coding and control architecture. Every addition had to work flawlessly with the legacy piping, structural supports and utilities already present at the site.
A Brownfield Upgrade with Zero Compromise
The image depicts the erection phase of a large structural steel Lattice Truss, typically used in industrial facilities for supporting overhead utilities, material handling systems, conveyor galleries, or plant access structures.
Our engineering scope included:
1. Mechanical & Piping Integration
- Development of test loop configurations tailored to turbine requirements
- Integration of new high-pressure piping with existing networks
- Design and analysis of critical flanges, valves, actuators and supporting instrumentation
- 3D modelling to validate routing, accessibility and maintainability
2. Boiler & Utility System Engineering
- Incorporating a dedicated boiler for generating required steam parameters
- Ensuring stable supply and control of temperature, pressure and flow
- Interfacing boiler outputs with turbine test gigs safely and efficiently
3. Instrumentation & Control Coding
- Specification and placement of transmitters, gauges, actuators and control valves
- Developing the coding logic for automated test sequences
- Ensuring real-time monitoring for safety, performance and precision
- Integrating these controls with the plant’s existing system architecture
Design Challenges and Engineering Solutions
Brownfield projects often present physical and operational constraints from confined spaces to ageing components. The turbine testing facility was no exception.
Purna’s team carried out:
- Detailed site studies to assess compatibility between old and new systems
- Stress and flexibility analysis for modified piping lines
- Interference checks using advanced 3D tools
- Support design accommodating both new loads and existing frameworks
- Material selection ensuring durability even where legacy components showed ageing or corrosion
The image above captures a part of this complex integration showcasing a mix of new actuated valves, instrumentation, steam lines and retrofitted components working together as a unified test loop.
Delivering a Future-Ready Testing Facility
By the end of the project, Purna delivered a fully engineered turbine testing environment capable of handling:
- Controlled steam and process fluid conditions
- Automated operational sequences
- High-accuracy testing and data collection
- Safe and reliable performance for repeated turbine test cycles
The upgraded facility now provides a robust foundation for validating turbine efficiency, endurance and operational reliability directly supporting the plant’s strategic objectives for product development and quality assurance.
Purna’s Commitment to Brownfield Engineering
This project reflects Purna’s strength in delivering multidisciplinary engineering solutions, especially in scenarios where precision integration and technical agility are crucial. From conceptual layouts to detailed 3D modelling and from coding interfaces to piping revamps, our team ensured that every design decision contributed to a safer, smarter and more efficient turbine-testing setup.
Purna's Engineers continues to support industries across India with high quality Mechanical, Piping, Civil, Structural, Electrical and Instrumentation design combining decades of experience with modern engineering practices.
