PRE-INSTALLATION CHECK LIST FOR VESSEL /

TANK / SILO WEIGHING SYSTEM:

A.STRUCTURE
A.STRUCTURE DETAILS:
DETAILS :

1. Strictly recommends only I-Beam support for the tank weighing

systems.
2. Load point of the load mount top plate & Bottom plate centre to be
matched with Central Axis of the ‘I’ Beam.
3. Recommends cross brazing between the base beams.
4. Cross brazing (Tie rod) to be provided between the legs of the tanks,
when the leg height goes more than 3 feet.
5. Checker Plate of the platform to be isolated from the Load mount and
the pipe supports.
6. Proper civil grouting to be provided for all leg supported vessel, if the
vessel is on concrete floor.
7. Isolation around the vessel should be minimum clearance of 50mm to
be maintained.
8. Accessing of the Load mount and Load cell clearance around the Load
mount should be minimum 500mm.

B.LEVELLING:
B.LEVELLING:

1. Spirit Level of load mounts base plate to be made perfect.

2. Water Level between load mount base plate to be made perfect.
C.PIPING
C.PIPING:

1. Common pipe work works between vessels may cause errors and
should be strictly avoided.
2. All incoming and outgoing pipelines should have proper flexible
connections.
3. Bellows are to be connected vertically then the Length of the bellow
should be 3 times of the dia of the pipeline.
4. Hoses (SS Braided hose) are to be connected horizontally then the
Hose length should be 7 to 10 times of the dia of the pipeline.
5. Ensure bellows / hoses should be flexible and should not act as rigid
pipe.
6. All flexible Bellow / Hoses to be supported in floor with proper grouting
or welding.
7. All Outlet Pipe line valves to be connected before flexible connection.
8. All Inlet pipe line valves to be connected, then the flexible connection
to the vessel to be connected.
9. Ensure and avoid the Pushing effect and pulling effect during
installation of the bellows.
10. Vessel Insulation to be isolated from the Load mounts base plate.
11. If vessel having high temperature then thermal pad to be installed in
between lug & the Load mount top plate.
12. Arrangement of necessary cable tray or conduits to lay the Loadcell
cable.
13. Mounting of JB and Indicator at the required location.
14. Laying the cable between JB and Indicator.
15. Arrangement of Standard weight for calibration after completion of
the mechanical works.
16. Necessary arrangement for keeping the weights on the vessel.
17. All welding work of weighing vessel & near to weighing vessel to be
completed before installing Load cells.
18. Power supply with proper ‘IS’ earth to be provided.
 Tank and Vessel Weighing
hi

Pocket guide

99-01-06-1 MU - 12/2008
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 The information and advice given in this guide are of a general
nature and supplied in good faith. PRECIA MOLEN cannot be held
responsible, in any way whatsoever, for the consequences of using
the information contained in this document.

* *
*

In this guide, for simplicity, the term “vessel” is often used to

describe any large container such as a silo, tan k, hopper or other
similar container.
 Contents
Contents.......................................................................................................................................................... 1

Introduction .................................................................................................................................................. 3

Definition of requirements ................................................................................................................ 4

Performance of a weighing system ........................................................................................... 5

Types of weighing ................................................................................................................................... 6

Level control .................................................................................................................................... 6

Batching and blending systems ....................................................................................................... 7

Fundamental design considerations ........................................................................................ 9

Definition of the measuring chain .................................................................................................... 9

Determining the number of load cells ................................................................................................................ 9

Pivots ................................................................................................................................................................. 10

Positioning the mounting assemblies ................................................................................................................ 12

Choice of load cell capacity ............................................................................................................................... 13

Level of the measurement signal ...................................................................................................................... 14

Critical aspects ................................................................................................................................ 15

Interaction between vessels .............................................................................................................................. 15

Pipes and walkways .......................................................................................................................................... 16

Retrofit installation ............................................................................................................................................. 16

Mounting ......................................................................................................................................................... 18

Mounting on the ground .................................................................................................................. 18

Mounting on the structure ................................................................................................................ 19
Special devices ............................................................................................................................... 20
Intermediate foundation plates .......................................................................................................................... 20

Tubular feet ....................................................................................................................................................... 20

Additional restraints and tie rods ....................................................................................................................... 20

Anti-lifting devices ............................................................................................................................................. 21

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99-01-06-1 MU 1
Influencing factors and disturbances ...................................................................................... 22

Temperature .................................................................................................................................... 22
Performance . ..................................................................................................................................................... 22

Mechanical disturbances ................................................................................................................. 23

Pipes .. ............................................................................................................................................................... 23

Forces induced by the wind ............................................................................................................................... 25

Earthquakes . ..................................................................................................................................................... 26

Electromagnetic interference ........................................................................................................... 27

Thunder storms ................................................................................................................................................. 27

Electrical interference ........................................................................................................................................ 27

Hazardous areas ............................................................................................................................. 28

ATEX Directive .................................................................................................................................................. 28

Installation and commissioning ................................................................................................... 29

Storage ............................................................................................................................................ 29
Mounting .......................................................................................................................................... 29
Levelling ........... ............................................................................................................................... 30
Load distribution .............................................................................................................................. 30
Welding ............ ............................................................................................................................... 31

Calibration ..................................................................................................................................................... 32

Preventive maintenance ..................................................................................................................... 33

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2 99-01-06-1 MU
 Introduction
The principal obje ctive of PRECIA MOLEN is to ensure th at our we ighing systems meet the
requirements and expectations of our customers in terms of performance, reliability and safety.

The experience we have acquire d in the field over many years shows that the success of a weighing
installation depends on :
• well designed equipment,
• good practice in mechanical design and engineering,
• correctly implemented fitting and installation,
• controlled commissioning and calibration procedures,
• routine service and maintenance.

This guide r eflects this philosophy. It wa s produced to assist persons responsible for designing and
specifying industrial weighing systems both for new installations and the modern isation of existing
installations.

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99-01-06-1 MU 3
 Definition of requirements
A precise definition of requirements will be beneficial and save valuable time and resources. This first
step is of major importance and we strongly encourage our customers to involve our company from the
beginning of the project.

A full definition of r equirements consists of a good un derstanding an d appr eciation o f the following
aspects :

Type of weighing :
- level control,
- single product (batch) or mixture of several ingredients,
- loss-in-weight,
- filling or dosing.

Product handled :
- thin fluids,
- viscous liquids,
- powders or grains,
- solids.

Conditions of operation :
- extreme temperatures with or without variation,
- corrosive chemical products,
- classification as ATEX zone, if applicable,
- nuclear environment,
- vibration (mixers, agitators),
- power-washing.

Ambient conditions :
- wind,
- storms,
- earthquake risk,
- rain, snow, ice,
- dust.

All these factors have an important influence on the accuracy and performance likely to be obtained. A
good definition of requirements gives a clear view of how the weighing system will operate.

PRECIA MOLEN can su pply a specification sheet to a ssist in e stablishing the gen eral outlines of the
project.

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4 99-01-06-1 MU
 Performance of a weighing system
Even though a weighing system has been desig ned to provide the desir ed level of perf ormance, the
accuracy obtained after the installation will be affected by a number of external factors and influences that
may seriously affect the actual performance of the system.

For example, when a product is dosed from or charged into a vessel, factors such as in-flight material
and impact and vibration f orces affect the p erformance of the system. External factors, such as wind,
excessive temper ature fluctuations or r ain can also contr ibute to the er rors in the system. All these
influences must be considered when calculating the accuracy of the weighing system. The method used for
calibration also has a very significant effect on the achievable performance.

At this stage, it is useful to define th e meaning of t he terms " accuracy" and "re producibility" more
precisely. These ter ms a re ofte n misunder stood, incorrectly used an d even confuse d. The relative
importance of accuracy and reproducibility depends on how they are used in the system ; the differences
are illustrated by the drawings below.

1 2 3

The archer’s shots in the first draw ing ( 1) ar e both r eproducible and accur ate. T hose in the second
drawing ( 2) are r eproducible but inaccur ate. As for those in the last (3) , they are neither accurate nor
reproducible.

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99-01-06-1 MU 5
 Types of weighing
It is important to have a thorough understanding of the use to be made of the weighing system and how
it will be operated.

 Level control
This type of system is frequently used for a simple check of the le vel of storage tanks. The accur acy
requirement for such systems may be fairly low ; also, the user may be tempted to install low performance
load cells and instrumentation. In practice, however, this may give unsatisfactory results, since the stability
of the zero compensation on this e quipment is often less than perfect and ther efore may not t ake into
account variations in ambient temperature due to an exposed location.

It may be that hoppers or storage tanks are not fully emptied for long periods. As long as they are not
empty, it is not possible to r eset the zero which may have changed because, for example , of dr ift or
temperature effects. During this time, the zero offset takes the form of an error in the indicated weight of the
product.

A user will not have great confidence in a w eighing system that displays a weight that fluctuates, for
example, bet ween day and night, while the tr ue quantit y of the product contained in the tank has not
changed.

Weight displayed: P + Z

Weight displayed: P

Zero at time t

Initial zero

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6 99-01-06-1 MU
 Batching and blending systems
In these systems, the actua l weighing is ca rried out over a much shorter period (gene rally severa l
minutes or several hours) ; consequently, it is possible to ach ieve grea ter accur acy than in the case of
storage tanks. Before starting a batch, the system is normally reset to zero, or tared, which minimises errors
due to fluctuations in the zero.

In general, in th e case of r ecipes, the vessel is also tared af ter adding each ingredient, w hich further
improves the performance.

However, it must be remembered that the accuracy of the weight of each ingredient depends not only
on the accur acy of the system itself, but also on the method used to add the ingr edients to the weighing
vessel : pipe, conveyer belt or screw-feeder. The response of any regulator valve or motor control directly
affects the weighing performance. For the user, the reproducibility or regularity of the batches may be more
important than the absolute accuracy of the weight of each batch.

Small additions to a mixture, for example additives, are normally weighed with much greater absolute
accuracy than the bulk ingredients.

A load may incorporate both bulk and minor ingre dients. If the a ccuracy required for each ingredient,
expressed as a percentage of its individual weight, is the same, that results in lower absolute values in the
case of minor ingredients.

For example , a ve ssel weighing system with a rang e of 5,000 kg may be specif ied w ith a n ove rall
accuracy of ± 0.1% of full scale, or ± 5 kg. If all the ingredients are to be weighed with an accuracy of ± 1%
of their individual weights, the 5 kg of uncertainty in the weighing is acceptable in the case of an addition of
1,000 kg, but is definitely not if only 100 kg are added.

Case 1 : addition of 1,000 kg Case 2 : addition of 100 kg

Ingredient Ingredient
correctly dosed incorrectly
(+/- 0.5 %) dosed (+/- 5 %)

Target Actual Target Actual

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99-01-06-1 MU 7
 Fortunately, the influences of the majority of theerrors in a weighing system are proportionately reduced
and experience shows that, for the example given, a weighing accuracy of 0.5 kg to 1 kg will be achievable.
This will enable the requirement s of the load to be met, without resorting to a weighing vessel of smaller
capacity for minor additions.

These figures ar e on ly gen eral r ules and ea ch application r equires indi vidual evaluation . When
examining an application, the complete measurement and control loop must be consider ed, the "weakest
link in the chain" being that which determines the accuracy.

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8 99-01-06-1 MU
 Fundamental design considerations
 Definition of the measuring chain
 Determining the number of load cells
The number of load cells used in a given system is normally governed by the design and shape of the
weighing vessel, combined with the level of performance required.

If the vessel is supported on feet, in most cases the number of feet determines the number of mounting
assemblies (1) and load cells. Vessels wit h three feet are simple to install because the load distribution on
the mounting assemblies is uniform. Vessels with four feet offer greater mechanical stability (2) of about 30%,
but generally require more careful adjustment to ensure that the four load cells are carrying identical loads
throughout the weighing range. Vessels fitted with more than four feet require a special study.

When the vessel is supported on a steel structure, it is the actual design of the structure that determines
the architecture of the installation and ther efore the number of mounting assemblies and load cells used.
The most common arrangements comprise three or four suppor t p oints uniformly distributed r ound the
circumference of the tank, as shown below.

In the majority of applications, the mounting assemblies can be placed symmetrically around the vessel.
However, in some cases, the positioning of the units may have to take into account the load offset induced
by some components, for example, motors and mixers.

The optimum position for the mounting assemblies can be calculated by using the relative moments at
each loading point to determine the load distribution.

(1) Or installation kits.

(2) The stability of a vessel is an important factor if it is very tall, in particular in external installations on sites exposed to the wind and
when the contents of the vessel are not distributed uniformly.

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99-01-06-1 MU 9
  Pivots
High accuracy weighing systems require the use of mounting assemblies fitted with load cells at each
point of support. However, for some weighing applications, it is possible to use a combination of active load
points (with load cell) and pivots. That may be an economical solution, depending on the nature of what is
being weighed and the accuracy required.

The couplings may consist simply of sections of I-beam or mounting assemblies without a load cell. One
of the advantages of using mounting assemblies is that these systems can be easily "upgraded" at a later
stage if required.

It is advisable to use pivots only in systems intended for weighing freely flowing liquids or solids. (See
next page.)
In fact, the accuracy of a system of this type depends on how the centre of gravity of the weighing system
moves in the hor izontal plane as the vessel is filled or emptied ; in ot her words, how the load distribution
changes between the load cells and pivots.

The calibration of weighing systems that include pivo ts requires special car e. The only tr uly effective
method consists in loading the vessel in a way that reproduces the manner in which it is actually loaded in
use. The most effective procedure for that is to use a flow meter (with calibrated flow rate - See “Calibration”,
page 32.).

Four support points Three support points

Mount with load cell Pivot

Horizontal tanks containing liquids are ideally suitable for the use of pivots. A support at four points will
require four pivots and two mounting assemblies with load cells, while a support at three points will use two
pivots and a single mounting assembly with load cell.

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10 99-01-06-1 MU
 Vessel with 3 feet Vessel with 4 feet
2 pivots and 1 mount 2 pivots and 2
with load cell. mounts with load
cell.

The illustrations show typical examples of vessels containing liquids, resting on both pivots and active
load cell assemblies. Pr ovided the necessary precautions are taken at the time of the design, installation
and setting up, an acceptable level of accuracy can be achieved.

The centre of gravity is likely to move while

emptying or filling.

In this application, it may be found that the position of the centre of gravity can move by a large amount,
when the product is removed from or added to the vess el. Also, the use of pivo ts and active load cells in
such a situation will result in significant errors.

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99-01-06-1 MU 11
  Positioning the mounting assemblies
Ideally, the load ce lls should be as cl ose as possible to, or even above, the cen tre of gravity of the
hopper or tank.

In many cases, that is impossible, especially when retrofitting an installation.

If load cells are installed to modernise a vessel fitted with particularly long support legs, the mounting
assemblies must also be placed as close as possible to the top of the legs.

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12 99-01-06-1 MU
  Choice of load cell capacity
Load cells supporting a vessel must be capable of withstanding :
- the maximum static load likely to be applied,
- any dynamic or shock load likely to be produced,
- any additional load induced by wind or earthquake activity.

Required capacity of the load cells

Dead load Overload

(wind, shock,
etc.)

Working load
Maximum operating capacity

Although it may be temptin g to increase the load cell range so as to cover any eventuality, that can
cause problems since the signal available at the output of the load cells may be reduced to an unacceptable
level. The load ce lls must provide an output signal per di vision of a suitable level, so that the associated
electronics can process it with the required accuracy. (See “Level of the measurement signal”, page 14.)

All the load cells in a given installation must havethe same capacity and be of the same type. They must
be installed so that each of them me asures the same share of the load throughout the w hole operating
range of the system. Ideally, the output signals from the load cells must be balanced at about 0.5 – 1.0 mV.

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99-01-06-1 MU 13
  Level of the measurement signal
It is necessar y to ensure that the measurement signal per division is large enough in relation to the
sensitivity of the indicator Ei.

This evaluation is essential, especially if the ta re weight is mu ch greater than the effective load to be
measured. The following inequality must be satisfied :

(Vsupp. x Sc x Cu x1000) / (N x Em x n) ≥ Ei

where :
- Ei ............sensitivity of the indicator (µV).
- Vsupp. ......load cell supply voltage (V).
- Sc ...........load cell sensitivity (mV/V).
- Cu ...........total load to be measured (kg).
- N .............number of load cells.
- Em ...........maximum range of the load cell (kg).
- n .............number of divisions of the weighing system.

In general, in view of the many influencing factors and disturbances, it is advisable to limit the resolution
of any system to 2,000 divisions.

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14 99-01-06-1 MU
 Critical aspects
 Interaction between vessels
The performance of any weighing system depends on the reproducible, linear deflection of the structure
above and be low the load cells. Any non linea r deflectio n of the str ucture will cause in correct weight
measurements.

Problems can ar ise when vessels shar e one or more commo n supporting beams, as shown below.
Weight changes in one vessel may affect the measurements of a neighbouring vessel.

The problem can be solved by using independent supports, as shown below. Not only are the vessels
now independent of each other, but in addition, th e diagonal supporting beams are shorter and therefore
less subject to flexing.

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99-01-06-1 MU 15
  Pipes and walkways
Care must also be taken to ensure that external accessories, such as l adders and walkways, do not
impede free movement of the vessels.

Common pipes and supporting beams betwee n vessels ca n b e t he source o f e rrors and should be
avoided as far as possible.

When a walkway links two vessels :

- it must not be rigidly attached at both ends ;
- sufficient play must be provided to permit expansion. Bear in mind that expansion and contraction
affect both the vessel and the walkway.

Take care that ladders do not apply undesirable forces.

 Retrofit installation
When adding load cells and mounting assemblies to existing structures, take care that the mechanical
integrity of the structure is not affected.

If exist ing hopper s or tanks are mounted dir ectly on the ground or on another structure , the act of
modifying them and installing mounting assemblies can lead to undesirable deformation when they are later
loaded. It may therefore be sensible to add a weighing cradle to the existing structure.

Even if mounting assemblies are designed to control lateral movement and uplift, they must only be
used with rigid structures and never be considered as contributing to the overall mechanical strength.

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16 99-01-06-1 MU
 The performance and integrity of mounting asse mblies depend on cor rect application of loads acting
vertically from top to bottom, along the principal axis. An angular offset or eccentricity of the load resulting
from a movement of the supporting feet introduces errors. In extreme cases, this can even lead to ejection
of the load cells from the sensor, with possibly catastrophic consequences.

After fitting the mounting Reinforcing

assemblies, deformation structure
may occur if the feet are
not sufficiently strong.

Simply fitting cross member s, or any other device to stiffen the structure, is gener ally sufficient to
prevent this problem arising.

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99-01-06-1 MU 17
 Mounting
Correct installation of the mounting assemblies is a key factor in a weighing problem-free installation
and op timum performance. PRECIA MOLEN mounting assemblies are specially designed to ensure
optimum performance under load, but it is of prime importance that the supporting structures, foundations
and weighed str uctures are designed, built and insta lled to pr ovide go od horizontal supp ort and are
sufficiently strong.

In a vessel weighing system, the load cells can be installed :

- either on the ground, on concrete blocks,
- or on top of the supporting structure.

 Mounting on the ground

In this ca se, the load cells must be capable of supporting the heaviest loads. T hey must also be a s
horizontal as possible.

To facilitate levelling and minimise the problems of im mersion of the load cells, the load cells and
mounts can be mounted on low plinths above the main foundations. (1)
For a neat installation, steel floor plates can be levelled using a high strength cement seal and bolted to the
top of each plinth. The vessel, to which the load mount s, without a load cell, are already attached, is then
lowered onto the plinth. Once the vessel is correctly positioned, the load su pport plates can be welded to
the floor plates on the plinths. This procedure ensures accurate positioning of the vessel, avoids problems
associated with n on-alignment of threaded holes and saves valu able time on site. ( See “ Intermediate
foundation plates”, page 20.)
When the welding and mechanical adjustments are complete, the load cells can be fitted into their mounts.

The intermediate High strength cement

Intermediate supporting seal for
foundation plate is foundation plate
not supported. the intermediate
foundation plate.

Very often, for economical and quick installation, fixing is by means of metal bolts. In order to avoid
weakening the plinths, this procedure must only be used if the fixing holes are at least 3 cm from the edges.

(1) If however the mounting assemblies are mounted directly on the ground, it is important that sufficient water drainage is provided
around the base.

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18 99-01-06-1 MU
 Mounting on the structure
Care must be taken tha t the deflection under load of the supporting members is both minimised and
uniform. Any difference in the deflection will cause inaccuracy, in particular in systems with more than three
load cells. T he mount ing feet m ust be sufficiently rigid in the hor izontal plane to pr event any flaring or
buckling.

Additional str engthening braces and

gussets may be used, as shown opposite.

It must be bor ne in m ind that an y

deflection of the stru cture will directly
affect all the pipes connected to it.

Note the reinforcements

between the flanges of the
section.

As shown in figur e B below, the pr incipal load axis must be directly below the cen tre line of the
supporting beam. This will prevent any twisting (figure A), which would have an undesirable effect on the
weighing performance.

Figure A Figure B

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99-01-06-1 MU 19
 Special devices
 Intermediate foundation plates
The major ity of PR ECIA MOLEN mou nting assemblies includ e a reinforced lower plate an d ma y
therefore be mounted directly on ste el or concrete stru ctures. In some cases, inst allers prefer to use
intermediate foundation plates to simplify the installation and gain certain advantages :
• it is no longer necessary to drill fixing holes on site,
• easier levelling of irregular ground,
• reduction in load on the ground. (See “Mounting on the ground”, page 18.)

The foundation p lates must for m an integr al part of the stru cture and welded, bolted or cemented in
place as appropriate.

 Tubular feet
When the load cell assemblie s are mounte d on vess els with tubular feet, the base plates must be
sufficiently strong not to be deform under load, as shown below.

 Additional restraints and tie rods

Although PRECIA MOLEN mo unting assemblies a re designed to limit both ver tical and horizontal
movement of the weighing vessels, additional bracing devices may be recommended for some applications.

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20 99-01-06-1 MU
 This is an important precaution when vessels are installed outside in location s exposed to the wind,
when the actions o f a process (vibrator s, mixers, agi tators, etc.) may cause excessive movement of the
vessel or when the installation is in an earthquake area.

 Anti-lifting devices
The fitting of anti-lifting devices is compulsory for vessels exposed to the wind or earthquakes.

These devices must however permit expansion and any

other normal movement of the structure. They must also
be str ong enough to withstan d the maximum for ces
expected and adequate ly fixed to the found ations or
support structure to prevent any possibility of pulling out.
They must be fitted in such a way as to limit any upward
movement to prevent damage to the load cellscaused by
the f orce o f th e r eturn shock produced w hen a vessel
regains its balance when the tipping force is removed.

Similar protection can b e provided by oth er mechanical

devices.

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99-01-06-1 MU 21
 Influencing factors and disturbances
 Temperature
Temperature is one of the most important factors to be considered when installing a weighing system.

Its principal effects are :

- expansion and contraction,
- creation of force shunts,
- the effects of thermal drift on the measuring chain (load cells and weighing electronics),
- the adverse effects on performance due to differential heating.

Thermal variations can give rise to considerable forces if free movement of structures is restricted. The
greatest care must therefore be taken in the design and installation.

Simple calculations can be used to determine the ch anges in the dimensions of the structures for the
commonest materials.
These are summarised in the table below for a temperature variation of 25° C.
Material Variation in length
By meter and by variation of 25° C
Steel 0.3 mm
Stainless steel 0.3-0.4 mm
Concrete 0.2-0.35 mm
Copper 0.4 mm
Aluminium 0.6 mm
Polycarbonate 1.6 mm
PVC 1.9 mm

Thus, for example, the diamet er of an aluminium vessel four meters in diameter will change by about
5 mm over a temperature range from -10° C to +40° C.

 Performance
The greatest care is taken in the manufacture of our load cells to ensure that they are fully compensated
for temper ature, which gives a st able per formance over nor mal r anges of operation. How ever, in some
applications, the load points must be pro tected from d irect e xposure to sources of heat, in pa rticular if
differential heating is likely to occur.

Rapid te mperature changes ( > 5° C per hour ) can also cause p roblems, but in this case simple
insulating measures are generally enough to restore the situation.

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22 99-01-06-1 MU
 Mechanical disturbances
 Pipes
Most vessel weighing applications require some pipe connections.

These act as interfe ring forces and may in troduce errors into the w eighing system. It is there fore
important to minimise their effects. It should be noted that pipes tend to have a relatively greater effect on
low capacity systems than on those of greater capacity.

Two principal effects must be considered :

• the effect of pipes on the rigidity of the system.
• the forces induced by expansion and contraction of the pipes.

In principle, well designed pipe systems should onl y marginally affect the perf ormance of a w eighing
system, whatever the type. Although the pipes effectively induce excessive rigidity in the whole system, if it
is flexible and reproducible, the effect of this will be compensated during calibration. However, in practice,
the actual reproducibility of the effects of the pipes may be fairly low. Consequently, for a weighing system
for which high accuracy is expected, lo ads and stresses due to the pipes must also be reduced as far as
possible.

For a given system, the total sum of the forces due to the pipes can be calculated, knowing the stiffness
of the various pipes and flexible couplings.

Expansion of the pipes

If the pipes are carrying hot liquids, whether they are process fluids or hot water in the heating jackets,
their expansion is greater than that resulting from normal changes in ambient temperature alone.
This expansion is opposed to that of the ve ssel ; consequently, suitable methods must be implemented
overcome these thermal variations.

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99-01-06-1 MU 23
 Recommendations

There are several ways of reducing the effects of the pipes :

1. Try to balance the distribution of the pipes around the vessel.

2. Fix long lengths of unsupported pipe.
3. Use 90° elbows as much as possible : they reduce the rigidity and absorb movement due to heating
effects.
4. Fit bellows or other types of flexible coupling to reduce the stiffness.
5. Be careful not to interpose pipe supports between the vessel and bellows or flexible couplings.
6. Try to avoid common pipes between vessel, or if pipes of this type must be used, ensure that a
change in load in one of the vessels does not affect the load in the other.
7. Avoid fixing pipes to floors or ceilings that are subject to random deflections.
8. Do not forget that electrical ducts or cable trays fixed to the vessel may cause the same types of
problem as the process pipes.
9. Take care to align pipe flanges and other couplings correctly. Do not strain the couplings during
installation.
10. If the pipes must be insulated, make sure that this does not cause problems of additional rigidity.
11. Do not forget that commissioning and calibration of the installation must be carried out after the
pipes are connected and the insulation added.

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24 99-01-06-1 MU
  Forces induced by the wind
The wind can significantly affect weighing vessels located outdoor s. The principal aspects to be
considered are :
- the integrity and safety of the system,
- the performance of the system,
- the risk of damaging the load cells.

The overall intensity of the forces generated depends on the geographical location, the shape of the
vessel and the proximity of buildings. The effects of these forces on the weighin g system depend on the
direction of the wind, the level of fill ing of the vessel and the height of its centre of gravity in relation to the
mounting assemblies.

Winds rarely blow at a constant speed and it is gusts that cau se the most damage. The effects of the
wind on installations with several vessels are especially difficult to predict.

In this guide, it is assumed th at the structure of the weig hing system and foundations is cap able of
withstanding the wind forces likely to be enco untered. If the lo ad cells are fit ted during modernisation to
vessels located outdoors, it is essential en sure that the structure w ill r etain sufficient strengt h after
installation of the load assemblies.

The forces induced by the wind consist of two basic components. One of these components acts in the
direction of the wind an d tends t o induce an overturning moment on the vessel at one or more mounting
assemblies, the second component is vertical and of smaller magnitude. Note that the horizontal force also
exerts a shear force on the load cell mounting assemblies.

Consequently, the latter must be capable of :

- withstanding the maximum loading of the vessel (dead weight + maximum capacity),
- counteracting the maximum overturning forces generated by the highest wind speed,
- withstanding the horizontal shear forces.

Information on maximum wind speed and direction is normally available from official sources for each
geographical region.

Horizontal force

The horizontal force (N) generated by the wind is given by :

Fh = kAv2

where :
- k ..............a coefficient varying according to the shape of the tank (cylindrical, square, etc.) and its
surface finish ; its value is generally between 0.6 and 0.8.
- A..............the exposed area of the vessel (m2).
- v ..............wind speed (m/s).

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99-01-06-1 MU 25
 This horizontal force induces an overturning moment defined by :

Fov = Fh x h/d

where :
- h .............the height of the centre of ac-
tion of the wind pressure above
the load cells,
- d .............the distance between the load
cells in the direction of the wind.

It may be difficult to calculate the exact position

at which Fhacts. For very tall enclosed vessels, one
can reasonably estimate h as half the height of the
vessel.

By substitu ting for Fh, the overtu rning force

(converted to kg) is expressed as follows : h
Fov = kAv2 h/(d x 9.81)

It is important to note that the horizontal force is

d
proportional to the square of the wind spe ed and
therefore increases rapidly as the wind speed
increases.

On some exposed sites, the wind speed may be

double that of the published speeds.

Vertical force

The intensity of the vertical forces generated by the action of the wind will depend on the shape of the
vessel and its orientation. In general, this force will not exceed 5% of the horizontal force. Any lifting force
will have the effect of reducing the indicated weight.

 Earthquakes
Weighing systems installed in recognised earthquake areas must be designed to minimise the risk of
failure of subassemblies or the complete system.

Calculating the forces involved is a complex task and it is advisable to take advice from specialists. It
should be noted that, depending on the location of the system, it may be compulsory to comply with certain
regulations. Even in countries which are not subject to intense earthquakes, small earth tremors sometimes
occur and installations in these critical areas (for example, the nuclear industry) may have to comply with
the requirements for seismic loads.

Briefly, to design a weighing system in an earthquake area properly :

• The load cells must be protected to withstand these types of forces,
• The measurement system must not weaken the structure, especially for an installation in critical areas.

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26 99-01-06-1 MU
 Electromagnetic interference
 Thunder storms
Thunder storms can seriously damage parts of the weighing system. Very tall vessels, located out of
doors, are particularly exposed to this risk, since they form excellent lightning conductors.

It is very difficult to provide total protection against this type of risk, but we offer special protection kits,
with advice to assist in minimising problems.

A few additional rules can be given :

• Provide a good earth. The upper and lower plates of each mounting assembly of an installation must
share the same earth potential.
• Take care not to allow ma terial to accumulate around the load cell and mounting assembly, that will
offer a current path, in particular in humid conditions.

 Electrical interference
It should be noted that electr omagnetic fields generated by processing equipment, such as mixers,
actuators and induction ovens, can pose serious performance problems to a weighing system. It is therefore
essential not to route the load cell cables close to the power supply cables of this type of equipment.

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99-01-06-1 MU 27
 Hazardous areas
Many pr ocesses involved in weighing are installed in a reas cla ssified as dangerous. T hese include
areas where sparks or heat sources can, under certain conditions, cause an explosion.

The determination of danger zones is based on the probability of a potentially explosive mixture of gas
and air – or dust and air forming. The ATEX European directive (94/9/CE) presented below classifies these
various zones.

Dust

Gas

Zone 0 (Gas) Continuous presence

Zone 20 (Dust) Continuous danger
Zone 1 (Gas) Intermittent presence
Zone 21 (Dust) Potential danger
Zone 2 (Gas) Occasional presence
Zone 22 (Dust) Reduced danger

 ATEX Directive
This directive applies to protection equipment and systems for use in explosive atmospheres.

Since July 2003, all installations (including weighing instruments) in an ATEX gas or dust zone, new or
old, must comply with European directives.

PRECIA MOLEN offers a complete ran ge of load cell s and weighing indicators that can be installed
directly in zones with ATEX gas or dust classification.

The installation of equipment in this type of zone is a complex subject and it is recommended that advice
be taken from our experts to ensure that the equipment complies with the regulations.

For a more detailed description of the subj ect, PRECIA MOLEN suggests the ATEX pocket guide
(ref. 99-01-01 MU).

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28 99-01-06-1 MU
 Installation and commissioning
 Storage
• Load cells must be stored in a safe place up to the time of their installation.
• Remember that large capacity load cells may be heavy.
• Take into account the regulations covering lifting.
• Never lift load cells by holding them by the cables.

 Mounting
PRECIA MOLEN load cell mounts can be levelled and aligned without risk of damaging the load cells.
In the same way, final we lding can be carr ied out in complete safety. T o fa cilitate installation,
PRECIA MOLEN mounting assemblies are designed as follows :
- either mounted on the weighing system with dummy load cells,
- or including a locking device dispensing with the use of dummy load cells.

The locking device must never be used as a jack to raise or lower the load.

The load cell cables must be protected with a flexible or rigid sheath. It is not advisable to cut the cables
for fear of degrading the performance.

After installation only, the load cell protection devices may be removed.
• For a mounting assembly with a dummy load cell, remove the dummy cell and replace it with the actual
load cell.
• For a lockable mounting kit, fit the load cell and unlock the device.

The load cell mounts give sufficient freedom in the horizontal plane to allow for structural deformation
due to temperature var iations. How ever, consider able forces can be exerted if movement is r estricted,
either by mounting assemblies that are incorrectly positioned, or by parts of the structure or pipework.

When installing mounting as semblies, note the ambient temperature in relation to the maximum and
minimum temp eratures likely to be en countered. A check must be then b e made that the mounting
assemblies have a comfortable freedom of movement over the whole temperature range. This is especially
important if differential expansion and contraction can occur.

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99-01-06-1 MU 29
 Levelling
Precise levelling of the mounting assemblies is essential for optimum performance. Experience shows
that the slope between the structure and the base plate must not exceed 1 mm per meter.

≤ 1 mm/m

 Load distribution
All the load cells in a system must carry similar loads when the vessel is loaded symmetrically.

In a system w ith three load cells, the loading is always statically defined, so that, even if one of the
mounting assembly is not exactly in the same horizontal plane as the other two, or deflects differently under
load, all three load cells carry the same load.
During commissioning, for systems with four load cells or more, it is generally necessary to adjust the level
of one or more of the mounting assemblies.

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30 99-01-06-1 MU
 To check the initial load distr ibution, the output signals of each load cell are measured pr ecisely and
compared. In a typical system, the differences must not exceed, and preferably be less than 10%, (normally
of the order of 0.5 to 1.0 mV.) If one or more of the load cells differs by more from this threshold, the reason
must be found. The problem may be due to offset motors or mixers. As far as possible, the load distribution
must be equalised by inserting shims between the upper surface of one or more of the mounting assemblies
and the corresponding vessel mounting.

Note that these adjustmen ts must be made after all the pipew ork has been connected and after the
vessel has been loaded then unloaded at least once (as fa r as possible). Car e taken in carrying out the
installation and levelling will minimise problems caused by unequal distribution of the load.

 Welding
No electric welding must be carried out near the load cells or instrumentation, since the very heavy
electric currents involved can damage them irreversibly. Consequently, all welding work must be completed
before fitting the load cells.

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99-01-06-1 MU 31
 Calibration
The overall initial performance of the whole weighing system depends directly on the method used to
calibrate the system during commissioning and the care with which it is set to work. It is at this sta ge that
the relation between the output signal from the load cells and the load actually applied is established. There
are several recognised methods, each with its own advantages and measurement uncertainties.

Before completing the initial calibration, the system must be loaded then unloaded completely at least
once to ensure that all the mechanical parts are correctly positioned.

It must be r emembered that ISO standard s stipulate that the calibr ation accur acy ( measurement
uncertainty) must be better than the required accuracy of the system, by a factor of at least three. That is
why the method of calibration chosen effectively determines the best overall performance that the system
can deliver from the start. Depending on the design of the weighing system, some me thods of calibration
may not be applicable, which in turn, will have an impact on the achievable accuracy.

Method of calibration Uncertainty of calibration load Required system accuracy

Standard weights ± 0.005 – 0.05% ± 0,015 - 0,15%
Working weights ± 0,025% ± 0,075%
Substitute load ± 0.025% ± 0,075%
Force transfer ± 0,05% ± 0,15%
Calibrated flow meter ± 0,03% ± 0,1%
Proving tanks ± 0,15% ± 0,5%

It is important to fix the method of calibration to be used at the preliminary definition stage, so that the
calibration procedure can be effectively implemented. This may, for example, require the fitting of additional
mechanical supports or attachment points for standard we ights. If calibr ation u sing a flow me ter is the
method chosen, ensure that an adequate water supply is available with means of draining it on the site.

Any calibration procedure must be capable of loading the system in steps up to at least 75-80% (ideally
100%) of the effective capacity. Calibrating a system over only part of its range, followed by extrap olation
of the results of calibration obtained for the low range, can lead to significant errors, especially if the system
is fitted with pipes and other force shunts.

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32 99-01-06-1 MU
 Preventive maintenance
Although our load cells and mounts are designe d for long term use in severe environments, r egular
preventive maintenance can avoid many untimely faults.

A periodical inspection of the installation can reveal situations likely to lead to problems : accumulation
of pr ocess pr oduct, local flooding or leaks from pipes. Simple cleaning procedures a re of ten enoug h to
prevent problems from arising : it is important to cure any leak from the process or solve problems of poor
drainage of fluids. The condition of the cables must be checked regularly.

The frequency of checks depends on the operational conditions and local environment, but must never
exceed six months.

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99-01-06-1 MU 33
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34 99-01-06-1 MU
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99-01-06-1 MU 35
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36 99-01-06-1 MU
 Contact us

 Commercial agencies in FRANCE  Worldwide installations

WEST FRANCE
ZI La Bougeoire - Rue de la Peltière  +33 475 66 46 00
35130 LA GUERCHE DE BRETAGNE e-mail:[email protected]
 02 99 96 14 43 - Fax: 02 99 96 14 44
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710 Chemin du Mitan
84305 CAVAILLON CEDEX NETHERLANDS
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 05 34 27 09 70 - Fax : 05 34 27 09 71
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Tel.: +353 18 35 30 84
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75 Rue de Gerland
69007 LYON GREAT BRITAIN
 04 72 73 00 22 - Fax: 04 72 73 11 13  +44 1527 59 03 20
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36 route de Thionville  +48 12 411 50 50
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57140 WOIPPY
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 +420 5 43 23 60 84
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ILE-DE-FRANCE/NORTH
Ch. de Gaulle Business Park
4, Ave Ferdinand de Lesseps MOROCCO
BP 707 - 95197 GOUSSAINVILLE  +212 22 70 69 05
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e-mail:[email protected]
INDIA
 +91 44 24542009/10/11
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 Head office and factory
BP 106 - 07001 PRIVAS CEDEX FRANCE
 33 (0) 475 664 600 - Fax: 33 (0) 475 658 330
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Illustrations are not contractual. Precia-Molen reserves the right to modify at any time, without prior notice, the information contained in this leaflet. RCS : 386 620 165 RCS Aubenas

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