Automation | FORCE Technology

Complete automation solution for calibration of the world's largest flow meters

Accurate measurement of flow is essential for the world's supply of natural gas. Danish FORCE Technology has built the world's largest closed loop for calibrating flow meters. Init, which is FORCE Technology's automation partner on the project, has been responsible for all programming of the automation system, which is based entirely on Schneider Electric's complete automation platform EcoStruxure.

 

When the experts from FORCE Technology open the valves in the company’s new MEGA loop in Vejen, natural gas flows through the facility at up to 60,000 cubic meters per hour. Comparatively, a typical family home uses approximately 1,000 cubic metres in an entire year.

 

The enormous flow of natural gas is necessary when the task is to calibrate some of the world’s largest flow meters. The meters can have a diameter of up to as much as one and a half meters and are typically located on natural gas pipelines that cross national borders.

Three people around a large pipe at FORCE Technology's MEGA Loop facility. One is wearing a t-shirt with Init logo

Challenge

Extremely high demands for process control

When dealing with such large pipes, it is crucial that the meters are calibrated to the highest possible accuracy. If they are not, it can cost many millions of kroner in incorrect settlements. And that is exactly what FORCE Technology’s new facility is built for. Therefore, it is absolutely essential that there is 100% control of the complex process to ensure accurate measurements.

 

Init and Schneider Electric have succeeded, aided by advanced management of the entire process using Schneider Electric’s EcoStruxure platform.

Three people sitting around a table. One has his bag to the camera and you can see a flow chart on hi laptop screen. There is a hard hat and a pot of flowers on the table.
Man with white hair and round glasses, wearing a dark blue sweater is leaning on a large pipe and looking at the camera.

We place extremely high demands on all aspects of the plant and its operation. This applies to safety in general, cybersecurity, operational reliability, and not least quality, durability and support for all the components that are part of the control system.

Niels Ole Rud Olesen, Senior Programmer at FORCE Technology

Solution

Advanced management of complex process

Init is FORCE Technnology’s permanent automation partner and turnkey supplier for the establishment of the MEGA loop. In close collaboration with the customer, we developed function descriptions for the facility to ensure that the result was the state-of-the-art solution that FORCE Technology wanted.

 

This solution involves a complete control system based on Schneider Electric’s EcoStruxure platform. The EcoStruxure platform enables you to build complete automation solutions with software, cloud services, and hardware in perfect, seamless interaction.

 

Init is a Schneider Alliance Partner, and our automation engineers therefore have deep insight into the entire EcoStructure platform. We have been in charge of developing and implementing the control system, which involved everything from design and programming to the construction of electrical panels.

Three persons around a PLC cabinet with green light on top. There are big pipes in the background.
Man leaning against a large pipe. He is wearing black t-shirt with Init logo looking into the camera

In collaboration with FORCE Technology, we chose to base the control system and all the electrical engineering entirely on software and components from Schneider Electric. We did this because both we and the customer already had strong knowledge of Schneider Electric’s products.

Jan Guldberg Larsen, Project Manager at Init

result

Easier troubleshooting & support

The fact that the solution at FORCE Technology is based solely on Schneider Electric benefits the customer by making troubleshooting and support much easier, since everything comes from the same supplier.

 

At FORCE Technology, Niels Ole Rud Olesen is very pleased with the new facility, and not least the advanced control system. FORCE Technology in Vejen already had several smaller facilities for calibration of gas flow meters, and the heart and brain of the new MEGA loop may pave the way for future upgrades later.

PLCs in a PLC cabinet

Obvious to use the experience

“We have had a very good collaboration with both Init and Schneider Electric, and our new plant is so good that we are now considering replacing the control systems on some of our other plants. It is obvious to reuse the experience and design from the new solution, so we achieve a uniform setup in all our facilities,” says Niels Ole Rud Olesen.

 

FORCE Technology’s MEGA loop in Vejen can calibrate flow meters for natural gas, biogas as well as the greener gas of the future with up to 25 percent hydrogen mixtures. In other words, the facility is prepared for the green transition of the energy supply to PtX (Power-to-X.)

Closed loop of natural gas pipes used for calibration of flow measurement.
To men with their backs to the camera facing slightly sideway looking at each other. Behind them a woman is looking at screen.

We have had a very good collaboration with both Init and Schneider Electric, and our new plant is so good that we are now considering replacing the control systems on some of our other plants.

Niels Ole Rud Olesen

Customer benefits

  • Advanced gas flow control for calibration of meters
  • Efficient user interface designed according to the ISA101 standard
  • Cybersecurity features built into controllers
  • Automation partner with deep knowledge of the entire EcoStruxure platform from Schneider Electric
  • Solution design can be reused later on other sites for uniform setup
  • One supplier = easier troubleshooting and support

Factbox

The technical details

Init was the turnkey supplier for the automation project, delivering a complete automation solution including:

 

Three small computer screens and one large screen placed in a factory setting with big pipes.

The automation solution itself is based on Schneider Electric’s EcoStructure solution with fully integrated software and hardware, i.e.:

 

  • Schneider Electric IGSS SCADA System
  • Powerful Modicon Controllers – M580 ePAC­
  • Altivar Process Drives
  • Harmony HMI Panels
  • TeSys Island Engine Starter
  • Easy UPS Emergency Power System
  • Switche
  • X80 I/O Modules with Ethernet
  • Preventa XPS Safety Controller
  • PowerLogic meters for monitoring power meters
  • Other switchboard equipment
Control system in a facility environment

About FORCE Technology

FORCE Technology is a technology consulting and service company that works to create positive technological change and make the world more sustainable and safer.

 

Since 1940, FORCE Technology has helped companies through major technological transformations and continues to help define the technological future.

 

With more than 1,100 employees in over 30 offices in 6 countries, FORCE Technology is a leader when it comes to specialist advice, testing, inspection and training. And as one of the major GTS institutes (Approved Technological Service) in Denmark, the company is also an important part of the backbone of the Danish innovation system.

 

Read more about FORCE Technology

Outdoor sign with FORCE Technology logo

Reach out

for more information

Johnny Frandsen

Head of Department & Project Director

+45 30 78 40 02

[email protected]

Init Troldhede, Denmark

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