Tank Weighing METTLER TOLEDO

1999, Mettler-Toledo (S.E.A.)

Guide To Tank Weighing Solutions
By METTLER TOLEDO
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
How Much Is In The Tank ?
To determine the actual amount of material in the tank for inventory
purposes or production process control
Tank Measurement Basics
Measurement Technology
Weight Sensing
Flow Meter
Probes
Level Sensors
Ultrasonic
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Flow Meter
Less Accurate
Shorter Life
Continuous Flow And Batching
Processes
Works Well With Liquid And
Slurries
Load Cell
Better Accuracy
Longer Life
Batching Process
Material Insensitive Works Well
With Gases, Solids, Liquids and
Slurries
Flow Meter And Load Cell Comparisons
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Flow Meter
Subjected To Material
Contamination And Corrosion
Effects
Not Easily Adaptable To Process
Changes And Material Changes
Load Cell
Not Subjected To Material
Contamination And Corrosion
Effects
Adaptable To Process Changes And
Material Changes
Flow Meter And Load Cell Comparisons
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Flow Meter
Separate Flow Meter Per Material
And Able To Control Simultaneous
Addition Of Materials
Less Mechanical Integration
Load Cell
One Scale Can Weigh All Materials
But Non- Simultaneous Addition Of
Materials
Require More Mechanical
Integration
Flow Meter And Load Cell Comparisons
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Learning About Tank Scales
Introduction To Tank Weighing
Weighing performance of a tank scale
Environmental considerations that affect the weighing performance
Tank scale design guidelines
Weigh module selection
Installation and calibration
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Weighing Performance
A Weighing Systems Performance Is Measured By :
Linearity
Hysterisis
Repeatability
Creep
System Resolution
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
0
10
20
30
40
50
60
70
80
90
100
Zero Hal f Load Ful l Load
Counts
Ideal
Actual
Linearity Error
Linearity is measured by a scales ability to correctly follow the linear relationship between the
weights applied and the displayed value. Linearity error is the maximum difference between the ideal
straight line and the actual curve at a given weight.

Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
0
10
20
30
40
50
60
70
80
90
100
Zero Hal f Load Ful l Load
Counts
Ideal
Actual (dec.)
Actual (i nc.)
Hysterisis Error
Hysterisis describes a scales ability to repeat the measurements for a linearity test when the scale is
loaded and unloaded.

Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
100 kg
100 kg
Repeatability describes a scales ability to repeat the same reading when the same weight is applied
and removed several times.
Repeatability Error
0.0 kg
+ 0.1 kg
- 0.1 kg
Actual Weight
100 kg
100 kg
100 kg
Displayed Weight
100 kg
100.1kg
99.9 kg
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Creep is the small change in the scales measured value of a constant load over a period of time due
to continuous mechanical deformation of the counterforce material.
80
82
84
86
88
90
92
94
96
98
100
0 15 30
Minutes
Counts
Ideal
Actual
Creep Error
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
500d 2000d 4000d
Load
Counts
0.5d
1.0d
1.5d
2.5d
0
-0.5d
-1.0d
-1.5d
-2.5d
Error
Counts
Resolution for a Legal for Trade scale is determined by the system capacity divided by the
minimum approved increment size following a given accuracy standard.
Handbook-44 Acceptance Tolerance Chart Class III Accuracy
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Resolution for a Process Weighing scale is only limited by the system capacity (Size
of Load Cells) and the sensitivity of the analog to digital converter in the weighing
terminal. The Displayed resolution can far exceed the Approved resolution or
Accuracy of the scale.
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Environmental Effects
Ideally We Can Have A
System Accuracy Equal To
The Load Cells Accuracy
Tank Design
Structural Integrity
Calibration
Installation
Tank Weighing System Performance
However, The System Accuracy
of a Tank Scale Is Influenced By
These Factors

Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Wind or
Seismic
Force
Wind or Seismic Loading
Wind and seismic forces can have a great affect on
tank scales, especially on tall narrow tanks
Upward, downward, and shear forces are exerted on
the tank and load cells
Use larger capacity load cells to accommodate for the
added loads
Mechanical restraints can be applied to maintain the
tanks position
Shield from the wind to minimize affects
Factors That Affect Tank Weighing Performance
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Shock Loading
Due to load dropped on the scale from A high point
exert strong forces that can damage the load cells or
tilt the tank
Using larger capacity load cells to accommodate for
huge shock loads
Use shock absorbing materials (Fabreeka

pads) to
dampen the loading
Use interior baffles and deflection cone to minimize
the shock load
Factors That Affect Tank Weighing Performance
Dropped Load
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Vibration
Induces electrical noise on the load cells signal
causing unstable and inaccurate reading
External vibration is caused by the surrounding
environment and structure is transmitted to the tank
Separate the surrounding structure from the tanks
support structure
Factors That Affect Tank Weighing Performance
External
Vibration
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Vibration
Internal vibration caused by sloshing of liquid due to
mixers agitation can be solved by using interior baffles
Use isolation Fabreeka

pads between the load cells

and structure to minimize vibration effects
The use of electronic filtering systems in the weight
indicators and terminals to reject the vibration
Factors That Affect Tank Weighing Performance
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Temperature Effects
Temperature can cause the tank to expand and
contract leading to A shifted and non vertical loading
on the load cell
It can also damage the strain gauges and cause
inaccuracy if used beyond the specifications of the cells
Insulation and low thermal conductive material
(Acetal/PEI) can be used in between the cells and the
tank
Factors That Affect Tank Weighing Performance
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Moisture and corrosive substances can damage the
cells physically and by shorting out its electronics
Cables and junction boxes must also be protected from
moisture
Debris collected on the load cells and tank will cause
weighing errors by mechanically binding the scale and
giving non-zero return errors
Proper cleaning and protection will prevent A failure
Factors That Affect Tank Weighing Performance
Moisture, Corrosion And Debris
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Electrical surges can cause permanent damage to the
load cells
Electrical surges may be caused by lightning, large
electrical machines or welding.
Providing single point grounding and surge protection
devices to the system can solve surge problems
Factors That Affect Tank Weighing Performance
Lightning And Surge Protection
Ground
Rod
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Rapid material flow in and out of tank causes an air
displacement and thus a pressure imbalance in the
tank
Weighing errors will be registered due to this air
displacement
Tanks should be built with vents or pressure regulators
Factors That Affect Tank Weighing Performance
Pressure Imbalance
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
A strain gauge load cells signal output is in millivolts
Any small change in the signal will cause a change in weight reading
RFI and EMI can induce electrical noise in the signal causing errors in the weighing
The effects can be reduced by using shielded and insulated cables which are properly grounded
Factors That Affect Tank Weighing Performance
RFI And EMI Effects
Analog Load Cell
Analog Electrical Signal
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Support structure deflection and non leveled supports can cause non-vertical loading leading to
linearity, repeatability, and accuracy problems
The tanks structure when loaded should be able to resist deflection, especially tanks with A large
diameter or long legs

Factors That Affect Tank Weighing Performance
Structural Integrity
Minimize
Deflection
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
The tank will not weigh accurately if there is any
mechanical binding to the tank from any component
that is not supported by the load cells
Piping connections to the tank will exert unwanted
forces that bind the tank when it is being loaded
Factors That Affect Tank Weighing Performance
Live To Dead Connections
Load Force
Reaction Force
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
To produce an accurate tank weighing system we need to make sure that the load is always
applied vertically and distributed evenly to all the load cells
To achieve this, the tank and its support need to be designed as level, rigid, straight and parallel
as possible
Tank Scale Design Guidelines
Loading Force Criteria
Vertical Load
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Tank Scale Design Guidelines
Loading Force Problems
Angular Loading
The load cell is subjected to an angular force
loading instead of A vertical force
Eccentric Loading
The load force is applied to the load cell at A
point other than its center line due to thermal
movement
Angular
Load
Eccentric
Load
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Tank Scale Design Guidelines
Loading Force Problems
Side And End Loading
This is due to horizontal forces that are caused
by dynamic loading, mounting misalignment of
the cells and thermal movement
Torsional Loading
The twisting effect on A cell due to structural
deflection, system dynamics and mounting
misalignment of the cells
Side Force End Force
Moment
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Tank Scale Design Guidelines
Loading Force Problems
Unevenly Distributed Load
Due to unleveled foundation supports and structural
deflection will cause linearity and repeatability errors
Support structures and foundation base should be level
(+/-0.5 degree) and in the same plane; Shimming can
be A solution
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Tank Scale Design Guidelines
Support Structure Design
The support bracket and base support structure should
not deflect more than 0.5 degree out of level
Top support brackets and bottom support structure
should be aligned and leveled
The center line of the load on A load cell should align
to the center line of the support beam to prevent
deflection of the structure due to heavy loads
0.5
Support
Bracket
Support Beam
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Tank Scale Design Guidelines
Support Structure Design
Using braces to strengthen the tanks legs to avoid
deflection
Adding web stiffeners or gussets to the support beams
can strengthen the beams
Use the same support beam sizes to avoid non-
uniform deflection which causes repeatability problems

Leg Braces
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Tank Scale Design Guidelines
Support Structure Design
Mounting load cells at mid-span of the support beams
will cause the most deflection on the beams at high
loads
It is better to mount load cells nearer to grounded
vertical columns
Reinforcement to the support beams is another
recommended solution to minimizing deflection
Grounded Vertical
Beam
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Tank Scale Design Guidelines
Support Structure Design
Tanks sharing the same support structure will have an
affect on each others weighing performance
Any movement and disturbances from one tank is
easily transferred to the next tank sharing the same
support structure
Tanks having separated and rigid support structures
will minimize tank interaction
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Tank Scale Design Guidelines
Check Rods
Excessive horizontal shear and uplift forces can
tip or rotate the tank out of alignment and cause
A non-vertical loading and also unsafe operation
Check rods and bumpers can be added to limit
this horizontal swaying and tipping motion on
the tank
Bumper
Bolts
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Tank Scale Design Guidelines
Safety Rods For Hanging Tanks
Safety rods will be needed for tanks that are suspended
in case the tension load cells suspension system fails
A safety rod is installed next to each tension load cell
and will have to be strong enough to support the tank
Safety Rod
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Piping connections need to be designed to exert minimal forces on the tank
Long horizontal pipe runs will exert less vertical force on the tank than short rigid pipe runs
A 90 degree bend on horizontal pipes will also make the piping more flexible
Tank Scale Design Guidelines
Live To Dead Connections
Horizontal Pipe Run
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Rigid piping supports should be located as far away from the tank as possible
Avoid rigid piping, use flexible connections along the pipe runs
Tank Scale Design Guidelines
Live To Dead Connections
Vertical Bellow
Flexible Hose
Flexible
Joint
Pipe Support
Maximum Distance
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Weigh Modules
Weigh Modules consist of a load cell and mounting hardware that converts the
tank to a scale and safely supports the tank
Weigh Module Selection Considerations
Tension or compression load cell
Number of weigh modules
Load cell metrological performance and size
Environmental protection
Weigh module mounting system
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Types Of Weigh Modules
Tension Vs. Compression Load Cell
Tension S-Type Load
Cell For Hanging
Tanks
Compression Beam Load Cell
For Ground Supported Tanks
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Tension
No Floor Space Required
Lighter Loading Due To Overhead
Structural Limitations
No Thermal And Compression
Effects
Compression
Floor Space Required
Heavier Loading Possible With A
More Rigid Foundation
Thermal Expansion And
Compression Effects
Tension Vs Compression Load Cell
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Tension
Normally Indoor
Heavy Wind Load Effects
Bumpers And Safety Rods Required
Less Surrounding Disturbances And
Effects
Compression
Indoor And Outdoor
Minimal Wind Load Effects
Uplift Protection Required
More Surrounding Disturbances And
Effects
Tension Vs Compression Load Cell
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Number Of Weigh Modules
The Number Of Weigh Modules is determined by the number of
supports on the tank
A 3-point support is ideal for tank weighing since the load is more evenly
distributed to the load cells, will not rock across corners
Four-module systems provide added stability under wind or seismic conditions
Weighing systems can consist of up to eight (8) modules
Level Detection systems use a combination of live and dead modules, lower
cost, lower accuracy
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Weigh Modules
Load Cell Metrological Performance
Important factors to consider are the linearity, hysterisis, repeatability, resolution
of the load cell to determine the accuracy
Typical Load Cell Performance
0.01 % R.C. Non-Linearity
0.02 % R.C. Hysterisis
0.03 % R.C. Combined Error
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Weigh Modules
Load Cell Sizing
Sometimes The Load Cell Size Is Increased To Compensate For Wind And Shock
Load Effects
Tank And Its Attachments Weight = A
Net Weight (Tanks Content) = B
Total Gross Weight = A + B = C
Number Of Cells = D
Load Cell Size = 1.25 C
D
Note: The 1.25 factor is for low weight estimates and uneven
load distribution
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Weigh Modules
Environmental Protection
The load cells and mounting hardware should have proper protection against
moisture, corrosion, extreme temperatures, shock loading or mechanical abuse
Hermetically sealed stainless steel load cells are better to prevent corrosion and
moisture effects
Load cells normally have an overload protection of 150% of full capacity for
shock loading effects
Always check load cells for their safe operation and compensated ranges of
temperature
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Weigh Module Mounting System
Compression Weigh Module Mounting System
The mounting hardware must always transmit the load
vertically from the tank support to a single point on
the load cell
To allow for thermal movement, the load pin should
not be bolted or fastened into the load cell
By bolting the load pin, the load is supported by the
threads on the load cell and not on the sweet spot of
the cell
Load Pin Vertical
Load Applied To A
Single Point
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Weigh Module Mounting System
Compression Weigh Module Mounting System
The weigh module system should incorporate
horizontal checking
Semi Floating Plate
Prevents Rotation Along
The Fixed
Fixed Pin Plate
Anchors The System
Full Floating Plate Allows Free
Movement In Any Directions
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Weigh Module Mounting System
Compression Weigh Module Mounting System
The weigh module system should accommodate for shifting of the vertical load due to thermal
expansion and contraction of the tank
Top Plate Allows
Movement
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Weigh Module Mounting System
Compression Weigh Module Mounting System
Hold-down bolt provides anti-uplift protection
Hold-down bolt eases installation and maintenance,
especially when replacing a load cell
Hold Down Bolt Serves
As Uplift Protection
And A Jack During
Service
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Flexmount

Weigh Modules
Stainless Steel/ Mild Steel Mounting Plates
Accommodates thermal expansion and contraction
Easy mounting for any type of vessel
Self checking, no check rods required
Hermetically Sealed Stainless Steel Load Cell
Washdown safe
Meets 5000 counts approved resolution
Hold Down Bolt Feature
Serves as A jack to support tank for installation
As an uplift protection

Weigh Module Mounting System
Compression Weigh Module Mounting System
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Weigh Module Mounting System
Tension Weigh Module Mounting System
The mounting hardware should incorporate a bearing
ball joint to prevent misalignment and keep the
loading vertical
Check rods or bumpers may be required to prevent
the tank from swaying
Secondary safety rods are needed as a back-up
suspension system in case of failure and to ease load
cell replacement
Spherical
Bearing
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Installation
Mechanical Installation
Preparations for foundation to be level, rigid and in the same plane
The tank should not be immediately lowered onto the load cells, use dummy cells
instead if the weigh modules do not have jack up bolts
Install the weigh modules where they can be easily accessible for maintenance
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Installation
Mechanical Installation
Shimming is sometimes necessary to ensure the load is evenly supported by the
load cells
The top and bottom mounting plates of the weigh module must be aligned to
avoid non-vertical loading
Never weld near the weigh modules without removing the load cells first, or the
welding current might pass through to the cells

Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Installation
Cabling
Properly shielded and insulated cabling is required
RFI and EMI can easily affect the microvolt signals of the load cells causing
errors
Properly grounded cables in combination with a ferrite ring will minimize RFI
and EMI
Isolate power cables from the load cell cables
Provide junction boxes with protection against moisture and corrosion (NEMA
4X / IP56)
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Installation
Cabling
Providing conduit for the cables will protect the cables from
mechanical damage and moisture
DO NOT cut or trim load cell cables as this will affect the strain
gauge load cells resistance and output compensation
Always check on the recommended size and distance for the home
run cable to avoid signal losses
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Calibration Preparations
Build brackets, evenly spaced around the tank to hang
test weights
Before calibration, each load cells signal output is
measured to ensure an even load distribution
If necessary, add shims for leveling of the modules;
junction box potentiometer trimming will compensate
for small differences in the outputs
Mounting Brackets For Hanging Test
Weights
Calibration Procedures
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Calibration Methods
Test Weights To Full Capacity (High Accuracy)
Possible to load test weights to full capacity on smaller tanks
Test Weight With Substitution (Good Accuracy)
10 -20 % test weights are used to perform the initial calibration and water is
used as substitution to be added with the weights to further test the scale to
full capacity
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Calibration Methods
Material Transfer (Medium Accuracy)
A material is weighed on A separate scale and transferred to the tank scale
and used as calibration weight
Electronic Calibration (Low Accuracy)
The use of an accurate simulator to produce the similar output produced by
the load cells at full capacity
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Maintenance
Periodically check and clean to avoid collection of debris on the tank, load cells
and junction box
Make sure that there is no mechanical binding on the tank
Any mechanical changes to the tank may affect the previous calibration
Inspect check rods and bumpers for proper gaps to avoid mechanical binding
Tank Weighing METTLER TOLEDO
1999, Mettler-Toledo (S.E.A.)
Finish
Thank You