Optimizing Natural Gas Testing Equipment with Advanced DAQ Control

High-Performance DAQ Test Architecture Drives Faster Cycle Times and Process Control

When evaluating the efficiency of industrial testing facilities, legacy infrastructure often creates severe operational bottlenecks. For manufacturers utilizing specialized natural gas testing equipment, achieving precise process stabilization requires an ultra-responsive control architecture. By implementing a high-capacity Data Acquisition (DAQ) control system paired with a high-speed DAQ test platform, companies can drastically reduce test cycle times, maintain tighter tolerances near critical phase boundaries, and secure the scalability needed for future expansion.

The Challenge

A leading manufacturer faced an urgent need to increase testing throughput for their specialized compressor products utilizing natural gas. The client’s existing setup featured legacy control systems and limited DAQ capabilities, which severely restricted the volume and variety of tests they could conduct. Central to the challenge was their reliance on a single test stand capable of handling natural gas equipment. This critical asset was heavily bottlenecked by long stabilization cycle times, which frequently took between four to eight hours to respond to step changes in testing conditions. The legacy systems lacked the physical room and processing capacity for future expansion. Mechanically, the client aimed to safely operate the test loop at precise conditions near the critical gas/liquid phase boundary, requiring exceptionally tight process control to prevent the mixture from accidentally crossing over into the liquid phase. To unlock their capacity, they required a modernized framework that could deliver faster loop responses, tighter tolerances, and superior data depth.

The Solution

ACS stepped in as the systems integrator to design, build, and deploy an integrated automation and high-speed data acquisition solution. To address the rigorous data requirements, the ACS team developed an advanced system utilizing NI™ VeriStand and PXi hardware, capable of high-speed data acquisition up to 20 kHz. This high-performance DAQ test architecture was engineered to handle complex channel configurations, automated test cycles, and real-time calculated variables displayed across a dual-screen operator interface.

For the primary control layer, ACS integrated an Allen Bradley Compact GuardLogix PLC to handle loop control, room ventilation, and critical safety features. This PLC system governs the temperature and pressure at both the compressor inlet and outlet. To drastically reduce the legacy 4-to-8-hour stabilization times, ACS modified the physical gas loop by adding Variable Frequency Drives (VFDs) to the loop cooler fans and cooling water pump, alongside modulating actuators on the cooler louvers.

Recognizing that the system operated in a hazardous environment, ACS built the main PLC panel and four remote I/O cabinets specifically rated for Class 1, Division 2 conditions. Additionally, the team fabricated a specialized DAQ control cabinet equipped with two instrumentation boxes mounted on new boom arms. Every cabinet and control element was designed with a substantial amount of extra capacity, ensuring the client has ample room for future expansion as their testing needs evolve.

The Outcome

The comprehensive upgrade delivered by ACS successfully transformed the client’s testing operations, drastically increasing throughput via automated, high-speed loop control. By replacing the legacy infrastructure, the new system achieved the tighter tolerances necessary for the client to safely run their natural gas equipment tests closer to real-world operational boundaries without risking phase crossover.

Through meticulous pre-planning and Factory Acceptance Testing (FAT), ACS seamlessly integrated the new hardware and software with the client’s existing equipment, minimizing costly test stand downtime during the field installation. The final commissioning of the full PLC and DAQ control platform provided the manufacturer with a highly responsive, stable, and expandable asset. Ultimately, the client transitioned from a restricted, slow-cycling legacy operation to a modern, high-speed DAQ test environment. This turnaround optimized the performance of their critical natural gas testing equipment and established a scalable roadmap for future facility growth.

Key Features

• Full commissioning of high-speed DAQ test platform (NI VeriStand with PXi hardware up to 20 kHz)
• Advanced PLC loop control with automated temperature and pressure management for compressor inlets and outlets
• Custom panel fabrication including a main PLC panel, four Class 1/Div 2 remote I/O panels, and an industrial DAQ control cabinet
• Integrated loop venting control valves and new VFDs for cooling fans and water pumps to maximize response times
• Expanded system capacity designed specifically to accommodate future growth and control modifications
• Minimal operational downtime during the integration and upgrade of the live natural gas testing loop

ACS Services

• Systems integration
• Controls engineering, design, and control panel build
• Integration with client’s existing equipment
• FAT and commissioning

View this case study on ACS’ NI Partner Page.