BLH Electronic le Weigh Systems Bo con Rao Handbook Table of Contents General Considerations KIS Beam Considerations Load Cell Considerations Load Cell Accessory Selection System Calbration Special Design Considerations Structural Design Piping Design Vessel Design Wiring Design —— oMah )contents Introduction. Goneral Considerations. Overview of Electronic Weigh Systems. Accuracy vs Repeatability Vessel Mounting — Tension or Compression. 7 Load Transducer Selection. Field Calibration KIS Beam Considerations. Vessel Restraints. Accessory Selection. Specific installation Procedures. Thermal Expansion or Contraction. Load Distribution for KIS Beams, Load Cell Considerations. Lateral Restraints — Stay Rods, Safety Check Rods. Load Cells in Compression Load and $-Cells in Tension. Specific Installation Procedures. ‘System Calibration. Special Design Considerations. Influence of Vessel Piping and Support Deflection Outdoor Installations ‘Are Welding on a Weigh Vessel Technical Data for Calculating Rod Lengths. Sizing of Lateral Restraints. Piping Flexibility Structural Design. ‘Support Deflection Load Transducer/Support Beam Alignment Diagonal Beam Support Vessel interaction. Siiffening Existing Structures Support Details — KIS Beams, Support Details — Compression Load Cells Support Details — Tension Load or S-Cells. Hydraulic Calibration Arrangement. Piping Design. General Rules. Sealed Systems. Vented Systems Vessel Design. General Rules. Wiring Design. -70 General Rules. coves TOintroduction ‘Since the beginning of trade, some kind of measure of weight had to be established. Not only did this measure have to be uniform, it also had to be honest. In order to weigh or measure anything, there has to be a standard for comparison. The equal arm balance scale or the unequal arm beam scale has been used for thousands of years as the standard for comparison. Iti still, by far, the most commonly used technique in the world for deter- mination of weight. However, approximately forty years ago a novel technique was invented to make electronic weight measurements reliable and economically practical. This invention was the resistance wire strain gage The strain gage consists of a filament of thin foil or wire which will change resistance when stressed Dr. Arthur C, Ruge of M.I.T. and E. E. Simmons of CalTech are credited with the simultaneous, but independent invention of the strain gage in 1937/38. Since each inventor had an assistant working on their project, and, since @ fotal of four people worked on the invention, the trade name for this strain gage became SR-4® (Simmons Ruge = 4 people). Professor DeForest, an inventor in his own right who produced a mechanical strain gage, encouraged Dr. Ruge in his work, From this relationship between two educatorsiscientists grew the Ruge-DeForest partnership which manufactured strain gages sold by Baldwin in the 1940's. In 1939, Ruge had signed an agreement with Baldwin Locomotive Works whereby he would design and manufacture SR-4® strain gages to be marketed by Baldwin This arrangement continued until 1955 when Baldwin-Lima-Hamilton (BLH), which had acquired Baldwin Loco- motive Works, bought Ruge-DeForest, Inc. BLH Electronics, with a history that spans more than forty years, offers a product jine that extends from basic sensors and signal conditioners to highly sophisticated, computer-based process control systems....plus all the related services from concept to start-up. Strain gages, as invented by Dr, A.C. Ruge, are now commonly used to determine stresses in a myriad of appl cations. The first electronic signals transmitted from the moon came from SR-4® strain gages attached to the three legs of the Lunar Surveyor. These strain gages measured the deflection of the legs upon impact with the moon. Scientists analyzed these signals and determined the consistency of the lunar surface, When a strain gage is bonded to a piece of metal and the metal is loaded with a weight or force, the resistance change of the strain gage can be related directly to the weight ar force placed on this piece of metal. The first industrial load, pressure and torque transducers using the strain gage technique were developed by Ruge in 1942 and 1943, These were rugged units with large overload capacities because the cells often were subjected to ‘excessive abuse by workers who were unfamiliar with the devices. Unlike today’s BLH high precision load trans- ducers, the early transducers were accurate only to 0.25% of full scale and available in limited weight capacities. Since then, BLH Electronics has made load transducers with the capacity of 4 milion lbs, to determine the ‘eight distribution of the Saturn rockets when moved trom the assembly area to the launching pad on monstrous ‘crawlers, to capacities of a few ounces in order to determine the number of food stamps in a given stack ‘The load transducer for electronic weighing has now been universally accepted. BLH Electronics has thousands of strain gage-based weighing system installations all over the world. It is the intent of this weigh systems handbook to help the user in avoiding some of the problems which may occur to degrade the accuracy of a weigh system. Many of the suggestions for this book came from the BLH Field Service Group. The book, therefore, is mostly practical with, here and there, a sprinkling of theory,\ The load transducer introduc! ion ‘The term ‘electronic weighing’ as used in this book is based upon the load transducer which derives its prin- cipals from the strain gage. The load transducer consists of an elastic element to which strain gages are bonded. Upon applying the mass to be measured to the elastic member, the strain gage wit! change its resistance in direct proportion to the mass applied. Load transducers, therefore, are electronic devices that translate changes in force into changes in resistance. Typical load cell, KIS beam, and S-cell construction is shown in the following illustrations, Cy maa cep q LU KIS BEAM CONSTRUCTION Sa oo CANISTER TYPE LOAD CELL CONSTRUCTION S- CELL CONSTRUCTIONintroduction Four SR-4® strain gages are used in each load transducer and connected in a fully active, four-arm Wheatstone bridge. Precision resistors are added at different locations in the circultry to compensate for temperature effects. Typical standard compensated values for load transducers are eight parts per million (ppm) per degree Fahrenheit for the output change with temperature and fifteen ppmi°F for the zero change with temperature. In order to protect the element from the outside environment, the sensing portion of the load transducer is en- closed in a sealed cover. Each load transducer sold by BLH has special inherent features to protect the sensing element from the effects of side loading. Why electronic weighing The majority of electronic weighing systems are used for one of the following purposes: REDUCE INVENTORY COSTS- Efficient and accurate control of inventory by weight allows the user to main- tain the optimum amount of material on hand for efficient production without costly excesses. Accurate inventory Can also result in a reduced number of storage vessels and area, contributing to further cost savings REDUCE LABOR COSTS - Process automation through installation of automatic batching systems can eliminate a substantial amount of manual input. Centralized inventory control readouts obviate the need for visual inspection of storage areas. IMPROVE PRODUCT QUALITY - Accurate batch control improves the consistency of end product quality resulting in improved product acceptance and reduces costly product rejects and rework Iti easily understood why an electronic weigh system has advantages over a mechanical beam type system. ‘Some of the advantages are: 1. Due to the low deflection of the load transducer, a load transducer based weighing system has a fast response or settling time. ‘The higher the capacity of the weighing system, the lower the cost will be of the weighing structure. Remote measurements can be made. The weight information can be processed directly to eliminate human error Microprocessor based instrumentation can communicate directly with programmable controllers or process computers, Electronic weighing systems often can be adapted to existing installations. 7. Load transducers and associated electronics are solid state devices and, therefore, are not subjected to wear such as found in the knife edges and supports in mechanical systems.Overview of electronic weigh systems Inits simplest form, a weigh system consists of a vessel whose contents are to be monitored, load-sensitive transducers that generate a signal proportional to the vessel weight, and an electronic device to power, amplify, interpret and display the signal. However, the accuracy of such a system, while obviously a function of the instrumentation, is also dependent upon the vessel design, support structure, piping attachments, lateral restraint system, vessel environment (tempera ture, traffic, nearby equipment), and proper selection of transducer accessories. In short, weigh system accuracy is inexorably tied to the degree of attention given to the mechanical details. HIGH ACCURACY WEIGH SYSTEMS exhibit system er10r3 under 0.05% for Buy-and-Sel to 0.25%. To achieve this, the following mechanical requirements are imposed. © The weigh vessel must be fully supported by trans- ducers. The number of load transducers may vary from one {in tension) to eight (in compression). Generally, as the number of load transducers decreases, the vessel wall thickness and support structure stiffness must increase to carry the higher vessel support reactions. © Precision load transducers with full temperature compensation must be used. Systems in compression general considerations © Mechanical restrictions from attached piping and lateral restraints should be avoided. Highly flexible piping attachments are recommended. © Hot gas or stearmheating schemes which produce variable buoyancy should be avoided. Consult factory for alternate solutions. © Pressurized or vacuum vessels also produce variable buoyancy, an effect which can be electrically compensated by means of a pressure transducer wired into the load cell circuit. LOW ACCURACY WEIGH SYSTEMS are those with a system error greater than 0.5%. Mechanical considera: tions are relaxed considerably: © The weigh vessel need only be partially supported by load transducers, usually ane or twoon any side or end of the vessel. This, however, requires. the contents to be selt-levelling and the vessel itself to be without partitions, so that the load fraction carried by the load transducers is un- changing. (Vessels faling into these two categories ‘must be fully supported, independent of the accuracy required.) © Modest mechanical restrictions may be tolerated, but nonlinear mechanical hangups or frictional interfaces must still be avoided © General purpose transducers are satistactory for these systems. VESSELS AT CONSTANT AMBIENT TEMPERATURE INDOORS / cam = 2a et fee HIGH ACCURACY FULLY SUPPORTED HEATED VESSELS OR VESSELS AT AMBIENT TEMPERATURE OUTDOORS KIS BEAM & [BEARING YOKE ‘ASSEMBLY Lt a HIGH-ACCURACY FULLY SUPPORTED vo KISBEAM FLEXURE sean ~] LOW ACCURACY PARTIALLY SUPPORTED canisTER TYPE {LOAD CELL BEAM TSE! LOW ACCURACY PARTIALLY SUPPORTEDgeneral considerations ‘Systems in compression HORIZONTAL TANKS ‘gh ACCURACY SYSTEM (1.5% ERROR OR LESS Ss == =f — nore onenrarion —- 0 —~ ea I cl SON zi oh rag ‘LOWER ACCURACY SYSTEM (GREATER THAN 5% ERROR xis tA ‘A horizontal tank supported by four KIS Beams yields 2 high accuracy weigh system independent of material location, A lower ‘accuracy system sultable for unpartitioned vessels with sel-leveling materials requires only two KIS Beams. ‘Systems in tension VESSELS AT ANY TEMPERATURE (Longths of Tension Flexure Rods are sized to accommodate radial thermal expansion) TENSION TENSION. §-CELL OAD eu Tension FLEXURE DS HIGH ACCURACY FULLY SUPPORTED LOW ACCURACY PARTIALLY SUPPORTEDAccuracy vs. repeatability © DONOT CONFUSE SYSTEM ACCURACY WITH REPEATABILITY! As long as the mechanical error ina given system is linear with deflection and in- dependent af the environment (temperature, traffic, surrounding vessels. etc), the inherent system repeatability will be greater than its accuracy. For example, a BLH Model 4315A Transducer In- dicator has an overall accuracy specification of 0.01% of reading, + 1 count, of which repeatability is but a small fraction. BLH load transducers, meanwhile, typically display a repeatability of 0.01 t0 0.02%. Thus, most BLH systems will be repeatable within 0.03% of full scale, independent of how the system is caliorated, © For most batching operations, repeatability is essential, whereas accuracy (actual pounds used) is of secondary importance once the operating parameters have been established. Field calibration, when required, is generally done by electronic substitution © For buy-and-sell installations, where distribution is by weight, calibration and repeatability are essential, field calibration is always performed employing a dead weight method. general considerations THEORETICAL accuracy EPERTARILITY 1 BAND ‘SYSTEM READOUT © DEFINITIONS, ACCURACY — Ability of the system to perform weighing functions within an acceptable or desirable tolerance; usually stated as a percen- tage of either full scale reading, or +n count(s) referred to the total number of scale divisions. REPEATABILITY — The ability of the system to read the same value when the measured ‘weight is applied repeatedly in the sane manner ‘with the same quantity under constant conditions. Vessel mounting — tension or compression Either method routinely yields high accuracy weigh systems and, except for the few observations presented below, there is litle to recommend one over the other. In most cases, plant layout is the determining factor. MAXIMUM WEIGH SYSTEM ACCURACY AND STABILITY willbe obtained when the vessel is mounted in compression on a rigid concrete foundation, This arrangement avoids all the usual sources of deflec- tion, variations in load transducer alignment, and. vibration that act to compromise calibration ac- curacy and operational stability. Therefore, when ex- treme accuracy is required (<0.05%), this approach should be considered first VESSELS WEIGHING UP TO 3,000 pounds are can- idates for the simplest system, a single canister type load or $Cell (BLH Model U3SB) in tension - providing that lateral restraints may be added if required to keep the vessel from tilting, swaying, and rotating,general considerations Vessel mounting — tension or compression (continued) Other considerations Design Factor Weight Limit Load Transducer Alignment Vessels not at Constant Ambient Temperature Lateral Restraints Sensitivity to Structural Support Vibration Compression Mounting Unlimited, as long as the number of vessel supports does not exceed eight; load distribution among the supports becomes very difficult there- after Canister type load cell alignment may vary during service due to overall floor deflection, local support beam twist, or vessel deformation causing small calibration errors, Low friction expansion assemblies or bearing yokes (KIS Beams) are required to accommodate differential thermal expansion or contraction between the vessel and support structure. Thermal insulation pads minimize heat con- duction to load transducers. Lateral restraints are usually unnec- essary in KIS beam applications, However, lateral restraints are almost always necessary for canister type oad cells, except when the vessel is. at ambient temperature, off in a corner, totally undisturbed, ‘function of the stiffness of the structure and vessel support structures. Some plant layout factors OPEN SPACE REQUIREMENT It the area beneath the vessel must be uncluttered, tension mounting is an option to be considered, Tension Mounting Usually designed to 10,000 - 20,000 gross weight since the structural reinforcement required for higher values becomes expensive, However, installations to 50,000 pounds per ‘support (200,000 pounds gross) have been installed. Cell alignment is unlikely to vary significantly in service since the tension flexure rods and spherical washers tend to accommodate local support deflections. Differential motion between the vessel and its support structure is, accommodated by adjusting the length of the tension flexure rods, Additional accessories are not required; the small sideload error introduced by friction in the expansion assemblies is avoided. May not be required for vented systems weighing nonhazardous dry products, free from structural vibra- tion, since a hanging mass is inherently stable. Tends to be more sensitive because of the reduced structural stiffness and damping capability caused by the tension linkage and the likelihood of the vessel's having a small mass more readily set in motion. ext FLOOR,general considera‘ Vessel mounting — tension or compression (continued) ‘Some plant layout factors (continued) WEAK FLOOR OR NO FLOOR HEAVY FLOOR When upgrading an older plant, where a convenient floor exists but is too weak to carry anew weigh vessel, or where there is no convenient structure, the weigh vessel may (GRATE WALKWAY require a special installation as shown here. = sur FLooR Lusk ROOF FOUNOATION fio suPront ‘STRUCTURE PRESERVES ‘OPEN SPACE. ACCESS FOR INSPECTION When processes must be monitored via vessel viewports, arrangements must be made such that the observer does not load the vessel viewPorT PERMANENT LADDER ‘SUPPORTED FROM FLOOR ONLY FLOOR ABOVE fOTATING FLOOR VIBRATION OR DEFLECTION QUIEMENT Avoid mounting a vessel to support structure subject to deflection or vibration from traffic or rotating equipment FLOOR BELOWgeneral considerations Vessel mounting — tension or compression (continued) Some plant layout factors (continued) LATERAL RESTRAINT INSTALLATION (Load and S-Cells) eae Ita weigh vessel requires some form of lateral restraints, consider which mounting configura tion best accommodates the installation ‘CEILING BRACKETS STAY 8008 TO FLOOR BRACKETS. STAY RODS on LATERAL sT0Ps: IN PLACE OF SAFETY CHECK RODS. OUTDOOR LOCATION Vessels situated outdoors are usually mounted in compression on a concrete slab to minimize construction costs and maximize vessel stability ‘When material is to be transferred directly from the vessels to trucks or railroad cars, the vessels, are sometimes elevated by a steel frame on conerete piers. a 1) 4 ss i We SLI SLI ee Cogeneral considerations Vessel mounting — number of supports This aspect of vessel design is fairly straightforward, as indicated by the following guidelines: UPRIGHT CYLINDRICAL VESSELS should have three supports, Load transducer installation is simplified since load distribution among the ‘supports is automatic: gapping between the load transducer and vessel support due to local sup- port structure deflection in response to traffic or vessel interaction is impossible for the sane reason - three points determine a plane. EXCEPTIONS arise when stability and cost effec- tiveness are major factors. Vessels requiring greater stability should have at least four supports; a round vessel with four supports is 22% mare stable against tipping than the same vessel with three supports. In this category are vessels exposed to high wind oF seismic loads, violent internal chemical reactions, of massive fluid sloshing as a result of agitation Vessels of large capacity such as coal silos in ‘excess of 1,000,000 pounds cannot be supported economically on just a few supports since vessel wall thickness and reinforcement increases as the number of supports decreases These vessels are usually designed with eight Supports, the maximum recommended by BLH Electronics. (Load distribution among the load transducers becomes problematical with larger numbers of supports.) ‘Small vessels weighing up to 3,000 pounds may be suspended from a single cell in tension Load transducer selection LOAD TRANSDUCER CAPACITY is determined in the following manner: Estimate vessel "tare" weight, the weight of the empty vessel plus attached piping, agitators, vibrators, insulation, and vessel heating fluids, as appropriate. Determine the maximum weight of the vessel contents, or “live load” ‘Add the tare weight and live load to obtain the gross vessel weight © RECTANGULAR VESSELS (HOPPERS, BINS) ‘generally have four supports, an accommodation to the vessel geometry, symmetry, and steel structural framework © HORIZONTAL CYLINDRICAL VESSELS usually have two saddles positioned symmetrically a short distance in from the ends. Three or four ‘supports are placed under the saddles, depending upon the stability and accuracy required LOAD TAANSOUCERS HIGH ACCURACY MAX. STABILITY rtm ne LOAD TRANSDUCERS. Tow ACCURACY MAX. STABILITY SINGLE FLEXURE BEAMS Loan TRANSDUCER Tow ACCURACY © Divide the gross weight by the number of vessel supports and multiply by 1.25 to yield the minimum recommended load transducer capacity. Gross Vessel Weight ee ee Number of Supports Where K = Dynamic Load Factor = 1 © The 1.25 factor is an allowance for low tare estimates and unequal load distribution on the load transducers as installed,general considerations Load transducer selection (continued) © In installations where dynamic loads are anticipated, such as vessels loaded with crane buckets, vessels with horizontal agitators, or dynamometer applica- tions, ‘derate’ the load transducer capacity by letting K = 1.25. This will provide greater assurance that the load transducer will endure repeated impact loads or high cycle fatigue. Estimate or calculate dynamic forces and con- sult BLH. © general rule of thumb for high accuracy weigh systems with K = 1is that the load transducer(s) should provide a minimum output signal of about 1,0mVIV over the range of live load. If it does not, consult BLH Electronics for specific recommend. ations on your weigh system requirements, since electronic techniques can be employed to in- crease accuracy at lower signal levels. LOAD TRANSDUCER TYPE BLH Electronics manufactures many types of load transducers to suit a variety of applications — general purpose, precision, high temperature, and rugged environment. General purpose trans- ducers are suitable for low accuracy systems; KIS Beams, with tighter accuracy specifications, are intended for high accuracy installations; high temperature transducers are for use at am- Field calibration VESSELS FULLY SUPPORTED ON LOAD CELLS © Calibration to 0.25% of full scale can be performed by electronic substitution using the BLH Model 625 Precision Calibrator or equivalent. This method assumes the vessel to be tree of significant mechanical restrictions; ie. all attached piping ccan be felt to move under a sharp blow of the fist; ‘no structural hangups will occur when the vessel is fully loaded. Barring any mechanical problems or unusually difficult vessel access, electronic calibration takes just a few hours. Note that load transducer cables should not be shortened sub- stantially when electronic calibration is used. © Calibration to better than 0.25% of full scale is usually performed with dead weights, the only method recognized by Weights and Measures ‘Agencies. Reter to the section on Special installa tion Procedures for a discussion of the techniques available. Systems in which maximum accuracy must be achieved should be at their uniform operating temperature when calibration is per- bient temperature above 130°F and incorporate ‘materials that function under continuous elevated temperature operations; ruggedized transducers are specially designed for mechanical abuse. Consult BLH Electronics for specific application recommendations. ENVIRONMENTAL PROTECTION Load transducers trom BLH Electronics may be. ordered with optional protective coatings to im- prove the life of the units under adverse en- vironmental conditions such as sea water im mersion and the presence of harsh chemicals Consult BLH Electronics for recommended coating systems for your situation, LOAD TRANSDUCER TERMINATION BLH Electronics typically supplies load tran- sducers with 10 feet of integral cable, Other lengths or types of cables for special environ- ments are available upon request CONVERSION FORMULA ‘Since some load transducers are specified in terms of ‘Newtons’, the following formula can be used to convert to pounds or kilograms, 1 Nevion = 0.225 Is = 0.102 kgs (appraximae gravitational equivalent) formed. BLH Electronics does not recommend dead weight calibration unless required for Weights and Measures certification or where accuracy of better than 0.25% is required VESSELS PARTIALLY SUPPORTED ON LOAD CELLS © It the main concerns repeatability, field calibra: tion is unnecessary, © tthe weigh system accuracy must be known, then calibration by the material transfer method is required. (Dead weight calibration cannot be employed since the exact vessel center where ‘weights would be applied is rarely precisely known or constant; ie. a slight change in slope of the vessel causes liquid contents to accumulate toward the lower (downhill) regions, shitting the CG and, consequently, the load fraction seen by the transducers.)Vessel restraints Selecting KIS Beam load transducers immediately resolves the problem of vessel restraint for most ap- plications. KIS beams are uniquely mounted such that the weigh vessel and the beam are united as one entity without undue friction or binding at the transducers, The KIS beam retainer yoke, which attaches directly to the vessel support bracket, completely encircles the beam itself. Since each beam is encircled by a retainer yoke, itis impossible for the tank to tip over. Should excessive side loading force be applied to the vessel causing an up- turning moment, the vessel can only rise a fraction ‘cusTomeR’s a ace nis |—YorE RETAINER THREADED SECTION IS BEAM VESSEL RESTRAINT, FRONT VIEW Accessory selection Bearing yoke Bearing yokes, which feature a teflon-iined bearing in the yoke assembly, are designed to allow the yoke to slide easily back and forth over the KIS beam as the weigh vessel expands and contracts. Bearing yokes are ideally suited for applications involving a great deal of thermal activity. KIS beam considerations of an inch until the lower block of the retainer yoke contacts the underside of the beam. Only under ex- treme conditions, such as heavy winds on a tall storage silo, would it be necessary to consider in- stalling safety check rods. Vessels mounted on KIS beams typically do not require stay rods. In rare situations where excessive seismic disturbance, agitation, thermal expansion, or vibration could potentially cause slippage of the retainer yoke on the beam surface, optional safety stop rings prevent the weigh vessel from sliding off the beam. VESSEL GUSSET VESSEL KIS BEAM VESSEL RESTRAINT, SIDE VIEW Dummy beams Dummy beams are used in place of KIS beams during mechanical installation procedures. Dummy beams are solid stee! shafts with the same dimensions as the corresponding KIS beam. Use of a dummy beam eliminates the risk of damage to the precision KIS beam due to stray welding currents andior mechanical impactKIS beam considerations Accessory selection (continued) Safety stop spacer Safety stop spacers, designed to keep mounting yokes {rom sliding off of KIS beams under extreme circumstances, are seldom required. In conven- tionally designed KIS beam installations where all beams face radially inward, safety stops are not KIS BEAMS IS BEAMS MOUNTED FACING RADIALLY INWARD 08 ‘OUTWARD DO NOT NEED SAFETY STOP SPACERS (SHOWN: KIS BEAMS FACING RADIALLY INWARD) Specific installation procedures Preferred method - dummy beam substitution To avoid damaging KIS beam transducers, BLH recommends that mechanical installation procedures be performed with dummy beams in place of the actual KIS transducers. Locate and attach yokes to the vessel support brackets using two mounting holes for each yoke (use four holes when thermal insulation kits are required). Install dummy beams in the mounting base housings Locate mounting base assembly, with dummy beam installed, under the yoke of each support bracket. Level each mounting base module to within %° (shim. ‘mounting bases as necessary) and lower the vessel onto the dummy beams. necessary. However, for exceptionally long horizontal vessels located out of doors (excessive thermal ex- Pansion and contraction), or a single KIS beam used in tension, safety stop spacers should be considered ‘SAFETY STOP SPACER LE KIS BEAM USED IN TENSION Make certain that each yoke is making direct contact, with (resting upon) its associated dummy beam. Un- der no circumstances should the retainer bolts be tightened so as to pull the beam upward to contact the yoke, The yoke should always be shimmed downward tocontact the beam Using a hydraulic jack, lift vessel ” only at each sup- port bracket, and replace each dummy beam with an actual KIS Beam, one at a time. Refer to the technical, manual, TM-KIS-1, for detailed instructions. Lower the vessel gently to avoid ‘shack’ damage to the KIS Beam Repeat KIS Beam substitution at each vessel support bracket. ‘Securely fasten all retainer yoke assemblies.KIS beam considerations Thermal expansion or contraction When application conditions suggest that vessel ex- Pansion or contraction, due to thermal forces, will be a standard feature of the overall process, bearing yokes should be installed at each vessel support bracket. Bearing yokes contain a teflor-lined bearing which allows the yoke to slide easily along the surface of the KIS beam. Slight yoke displacement from the recommended beam load point will not greatly affect the system accuracy or repeatability, as each millimeter of displacement yields only a 0.005% change in calibration. Bearing yokes should be con- sidered if the vessel is to be mounted out of doors or if the vessel will be used at a temperature other than ambient. Load distribution for KIS beams © Shim mounting base (first) Once the correct mounting location has been determined for the base assembly, metal shims must be used to level the assembly in both length and width. Stagger shims or shim segments be- tween the base assembly and the mounting sup- Port, as shown in the illustration below. Tighten securely and check that the base and beam as- sembly is plumb within ¥4°. The side to side level ‘snot critical since the KIS Beam can be rotated in the housing to coincide with the load direction. Do ‘not disturb the base assembly after itis plumb. SHINS ‘SHIM AS NECESSARY Hor vesset PERIMETER ‘Shim for load distribution With empty vessel weight resting on the KIS beams, measure the output of each beam with a readout instrument such as a BLH Model 3528. Transducer Indicator. Each beam must indicate some output representing partial weight of the empty vessel. Normally, readings should be from 1 to 10mVde. No beam should indicate less than 10% of the empty vessel weight; ideally each beam would indicate a proportionate share. Any beam outputting less than 10% of the vessel weight must be shimmed between the yoke and vessel mounting point. Ita gap exists between the yoke and KIS beam, determine the gap size, raise the vessel, loosen the yoke mounting bolts, and add shim material equal to the measured gap plus 015 to .030 inches. if no gap was measured be- tween the beam and the yoke, yet a low output was measured, insert a trial shim of .01 to .030 inches and recheck all beams for proper weight, distribution. Repeat this shimming measurement procedure until ali beam outputs read within 20% of each other.load cell considerations Lateral restraints — stay rods, safety check rods PARTIAL LISTING OF OPERATIONAL AND. ENVIRONMENTAL ELEMENTS ACTING TO DISTURB AVESSEL LATERAL RESTRAINTS are mechanical devices designed lo secure a weigh vessel to the structure, thereby maintaining initial alignment throughout service life, Unlike unweighed vessels with support brackets that may be bolted or welded directly to the structure, weigh vessels mount on load cells that provide only vertical reactions at one point under the Support bracket; while there is some restrain! available through friction, employing it would be detrimental to weigh system accuracy. So, with few exceptions, itis aduisable to apply some form of restraints to all weigh vesse's for reasons of SAFETY - Attached piping can be fatigued or ruptured, of vessels can be upsel by unrestrained vessel motion in response toa number of forces. prevalent at industrial sites, Systems containing hazardous materials are of particular concern. WEIGH SYSTEM ACCURACY AND STABILITY - Vessel translation, vibration, of oscillation must be properly controlled or system calibration accuracy and stability cannot be maintained. For example vessel transiation can apply sideloads on the rans: ducers causing readout errors; vessels vibration and oscillation generate variable signals which may impair the system response or control functions. STAY RODS, SAFETY CHECK RODS - Experience has shown the use of tension straps to be a simple, but effective, means to vessel restraint. In the usual con- figuration, straps are arranged in pairs - one pair for ‘each load cell on the vessel, positioned symmetrically about, and tangential to, the vessel, BLH Electronics defines two categories of tension straps. STAY RODS constitute the primary lateral restraint system on most vessels and are intended to rigidly constrain or stay” the vessel. These rods are: installed snugtight between a gusset on the vessel support bracket and a rigid floor bracket a few feet away. Vessel translation or rotation is thus restricted, while radial thermal expansion is relatively un: impeded. Because stayrods are snug fo the vessel, INTERNAL TO VESSEL. fluid sloshing Violent chemical reactions Material entry and exit (thrust and impact forces due to mass flow) EXTERNAL TO VESSEL vibrators or live bottoms agitators thermal expansion of attached piping structural support vibration from rotating equip- ment or traffic structural support detection rom adjacent vessels, equipment or trattic potential impact from traffic or overhead crane wind seismic events other expected events they are an active part of the weigh system and must be installed level to ensure a linear response with detlection. Rules for sizing stay rods are presented in the BLH publication entitled 'TECHNI- CAL DATA/Sizing of Lateral Restraints’ (TD 088), SAFETY CHECK RODS are backup members whose sole function is to hold the vessel in check’ Preventing gross tipping or wobbling, These straps are installed with a loose fit so that they do Not interact with the weigh vessel even after thermal growth, but simply contribute to the vessel tare weight. Satety check rods may be positioned at vessel elevations other than the plane of support to guarantee stability for those vessels with large height-lo-width ratios, such as tall storage silos.load cell considerations Lateral restraints — stay rods, safety check rods (continued) SAFETY CHECK ROO {WHEN REQUIRED) LOCATE AT FULL LOAD CENTER.OF-GRAVITY ELEVATION ore: ‘STAY RODS TO BE AS CLOSE ‘TOTHE PLANE OF VESSEL ‘SUPPORT AS POSSIBLE INSTALL RODS LAST; SET LEVEL TO WITHIN = 14" bn STIFFENER STAY ROD (TENSION ONLY) oversizeo CLEARANCE HOLE Lops GAP (TP BOTH ENDS) FLOOR BRACKET SET PLUMB TOWITHIN = ico SUPPORTING STRUCTURE: DEFLECTION ESSENTIALLY UNIFORM AT EACH CELL ‘LOCATION TYPICAL ROD ARRANGEMENT STAY ROD installation considerations: By terminating the rods at brackets adjacent to the vessel and separate from the building structure, the rod end deflection is effectively limited to the load cell compression (0.010") or tension linkage elongation (0.030") rather than the much greater overall floor detlection between the vessel and structure. The likelihood of significant mechanical restriction arising from stay rods is greatly reduced, The majority of vessels have support brackets located rear the maximum center-of-gravity elevation; many of the disturbing forces (e.g., seismic or wind) act, at or near this location. In this case, installation of the rods at the brackets removes these forces at the point of application leaving the vessel relatively unloaded, By terminating the rods at a gusset plate on the ‘vessel support bracket, a separate reinforced attach ment area on the vessel wall and a separate stay rod fitting are avoided: thermal expansion between the plane of support and rod attachment point becomes trivial; and the restraint may be located outside the vessel insulation, simplifying installation, ‘The use of floor brackets provides more open space around the vessel, enhancing access to the vessel.load cell considerations Lateral restraints — stay rods, safety check rods (continued) LATERAL RESTRAINTS are not necessary for vessels systems). Refer to “Piping Design” section for that meet all requirements listed suggestions Essentially static contents; no significant agitation ‘Slow material flow rates (sealed systems). or vibration Mounted in tension or rest on fixed mounting plates. Essentially static environment; no possibilty of large external forces such as wind, excessive support OBSERVATION. structure vibration, wayward forklift, or seismic event (seismic zones 0 to 1 only). Three or more supports. ‘Should minor disturbances be present or expected, safety check rods or some form of bumper may be added to preclude large vessel motion. This is Plane of support is near maximum center-ot-gravity possible only for vessels that will return to their (CG) elevation. original position after the disturbance is over; e.9., Either no direct piping contact (vented systems) or vessels supported in tension or compression at or only very flexible nonmetallic connections (sealed above their maximum CG elevation VenTeD sysTem {any tempore) PLANE OF ‘SUPPORT ELEVATION SEALED SYSTEM (any temperature) PLANE OF ‘SUPPORT ~ MAKEload cell considerations Lateral restraints — stay rods, safety check rods (continued) LATERAL RESTRAINTS not necessary for vessels meeting all requirements listed on Page 18, SEALED SYSTEM (ambien PLANEOF /} ‘SUPPORT CLEARANCE _ Re Special Case: Vessel center-of-gravity above plane of support Storage vessel off ina comer, totaly undisturbed, contents nonhazardous axe PLANE OF ‘SUPPORT LATERAL RESTRAINTS are essential for vessels gravity (CG) elevation subjected to one or more of the following: Top heavy or heavy off-centered auxiliary equip- ment. Low friction expansion assemblies are used; restraints required to maintain intial vessel alignment. OBSERVATION: Very active contents; sloshing or violent chemical When the significance of disturbing forces is un- certain, itis good practice to design the restraint Active environment: wind, structural vibration, aay bee system, provide attachment points on the vessel, vetile het, or igh seismic actly zone (Zone 2 and then see how the vessel functions in operation. If restraints are required, the space should be available and the restraints can then be added reaction Large agitator or vibrator (Refer to "Special Applica- tions” section for suggestions on vessels with vibrators) Plane of support well away from maximum center-of-load cell considerations Lateral restraints — stay rods, safety check rods (continued) LATERAL RESTRAINTS are essential for vessels subjected to one or more of the factors listed on Page 19 ee — umevese, 227 auton 004 wn Z Ze RXPANSION ASSEMBLIES AGITATOR “ZZ. wusuPeRsTaUCTURE _ ee wn = Sab eeeeeeeeeceee coneeresuront mo y STAY RODS, PLUS VERTICAL RESTRAINT RODS INSTEAD OF CHECK RODS VESSELS ON EXPANSION ‘ASSEMBLIES fl STAY RoDs CHECK RODS NOT AequineD, CUTOUT WITH BUMPERS 13 ‘ADEQUATEload cell considerations Lateral restraints — stay rods, safety check rods (continued) LATERAL RESTRAINTS are essential for vessels, Subjected to one or more of the factors listed on Page 19. VESSELS WITH OFFSET cos suack. HEAVY AGITATOR CHAIN HECK Roos EXPANSION ASSEMBLIES ‘aKD STAY RODS FIXED MOUNTING PLATES AGITATOR ING WITH ‘CHECK RODS BASE SUPPORT FRAMEload cell considerations Lateral restraints — stay rods, safety check rods (continued) LATERAL RESTRAINTS are essential for vessels, subjected to one or more of the factors listed on Page 19. e eAVY aGrTarOR TAL ‘CHECK RODS (to nat foro eating) STAY RODS VESSELS BOTTOM moUNTED VESSEL IN SEISMIC ZONES 2 AND 3 CHECK RODS ‘ATATOR i<—_— HIGH FLOW ATES. cee ‘00s “ie Rs PATTERN FOR BOTH SETS OF RODS,load cell considerations accessory selection and installation Load cells in compression General rule for compression use Attach load cell to whichever surface is more rigid, the vessel support bracket or supporting structure. ‘The load cell should not deviate from initial plumb Fixed mounting plates Vesset cawuminum, FIBERGLAS) BEARING PLATE LoaD Plate 7 ‘STRUCTURE MORE ‘cio Expansion assembly Accommodates thermal expansion or contraction of a vessel relative to support structure with minimum sideloading of load cell. Generally necessary out- doors and indoors when vessel temperature differs from ambient. The load cell is usually installed with load button down for convenience. VESSEL OR during service, or calibration accuracy may be com- promised. When the choice is not apparent, mount load cell with load button down, VESSEL MORE iD BEARING pate" BEARING PLATE — 3 Thermal insulation pad Reduces heat conduction from heated vessel to load cell allowing load cell temperature to remain close to ambient; temperature effects on performance are thus minimized and calibration accuracy is preserved, The pad is made of a rigid glass-cloth laminate with extremely low thermal conductivity, vesseL WALL vesse. sont mage THERMAL rer EXPANSION ASSEMBLY INSULATION PAD muon ss sv . sta wro ce Wo Tea tono Stavouna oan ce ao Surton oan cee gtin txpanson ase. owas Suton ™ . 7 a ™ VESSEL TEMP. To 130°F Above 130°F Above 130°F AMBIENT TEMP. To.130°F To 130°F 190°F To 425%load cell considerations accessory selection and installation Load cells in compression (continued) Installation tools These simulated’ assemblies duplicate the critical dimensions of the corresponding load cells and accessories for use in place of load cells during vessel installation. Eliminates risk of damage to precision load cells due to stray welding currents and mechanical impact. HOW TO USE Order simulated assemblies when placing load ell order for delivery in advance of load cells. ‘Simulated load cell and fixed mounting plates os mig Hales acTuaL SIMULATED Flexure beams Flexure beams can be substituted for load cells and fixed mounting plates in lower accuracy weigh systems. Flexure beams are generally used for onagitated vessels containing selt-leveling materials, operating at constant ambient tem- perature. Install simulated assemblies; make all piping connections, weld, insulate, etc. When vessel work is complete, jack each vessel support {”, remove simulated assembly, replace with oad cell and accessory, and gently lower vessel Shim as required to plumb load cells and equalize tare weight among the cells, ‘Simulated load cell and expansion assemblies fea] fees Fol tg Hoes Leper ACTUAL SIMULATED APPLICATIONS: Align beam webs so vessel can pivot with load cell deflection, thus providing a flexibility to vessel Support that may not occur when web is opposed to cell deflection. 2load cell considerations accessory selection and installation Load cells in compression (continued) Bearing Beams Bearing beams, substituted for load cells and ex- pansion assemblies in lower accuracy weigh systems, are generally used on vessels containing self-leveling materials with no agitation. Since gussets are required to preclude buckling of the beam web, negligible beam motion occurs under vessel expansion: all vessel growth must be ac- ‘commodated by the expansion assembly. Square hale pater except or 200,000 8 capacity beam APPLICATIONS: Align beam webs so vessel can pivot with load cell deflection oxo oxuus ono cet exh ASST Pi cep ASS vesset axis © e wes we Loam cet. * seam: ex.s Stay rods Safety check rods Stay rods provide positive lateral restraint for vessels, with agitators or vibrators; hold vessel centered on for unlikely events — high wind, seismic, wayward fork expansion assemblies so full design travel is assured. _ift, etc — when vessel center-ot-gravity is above Since stay rods are an active part of the weigh system, support plane (and stay rods). Check rods are normally install level to ensure a linear response with deflection, _passive members, adding only to the tare weight of the vessel ovensizeD SAFETY CHECK ROD Cleasance O (WHEN REQUIRED), Safety check rods provide back-up restraint capability LOCATE AT FULL LOAD ‘CENTER-OF-ORAVITY Ee ‘rve! BOTH ENDS) 4 i NOTE: STAY RODS TO BE AS CLOSE "TO THE PLANE OF VESSEL aoe ‘SUPPORT AS POSSIBLE STAY 00 INSTALL RODS LAST: crensiow oLy) sent ToMn saan onacrr je ser Cone 21° rane or suronr [ef be BP ain surronnne srucrure earnest _ vnromat gene TYPICAL ROD ARRANGEMENTload cell considerations accessory selection and installation Load cells in compression (continued) Stay rods for horizontal tanks on load cells and : y ap fixed mounting plates / wee ES 2 ei General rule | Locate lateral rods close to the ends of tank for SS - maximum leverage against piping moments tending | | to rotate the tanks. \ Fs \ vedset -—-—|+- anacaer AXIAL LATERAL, a fons “Roos sano sniening | mate sanoue sracner ~ = (Opton) vesset Loo | shacner anacKET SS a id Trea wur eS ‘APPLICATION Stay rods for horizontal tanks on load cells and Aap _ esse, flexure beams YG erty General rule { = = Locate lateral rods close to ends of tank for maximum |, _ + Y = leverage agains piping momentstending orotate | the tanks. yl Namie ( xia LATERAL FLEXURE BEAMS PRoviDg 00s LATERAL RESTRAINT saonue sanote Racker . ~ (Opten) 1 008 mace RACKET ALLTANKSload cell considerations accessory selection and installation Load cells in compression (continued) Stay rods for horizontal tanks on load cells and expansion assemblies General rules. maximum leverage against piping moments tending tod due to tank thermal expansion. (On longer tanks, Locate vessel-mounted axial restraint brackets elongation under load.) Ae oes = i al | | ee © wxiat aos ‘STIFFEWING sapoue ‘RACKET (Optin) F.o0R i BEARING SEAMS PROVIDE _LONBRODS TO ACCOMMODATE Stay rods for horizontal tanks on load cells and etree eee bearing beams estmaretve, ¢ = es / keV a soa (GUSSETS PREVENTS BUCKLING OF BEAM WEB) Foon BRACKET| STAY ROD Langin =50 6 VESSEL EXPANDS RELATIVE TOTHIS PONT {LOAD CELL AND "EXPANSION ASSY.load cell considerations accessory selection and installation Load cells in compression (continued) Stay rods for hoppers and bins, any temperature { —=—s= > esse Fon : aacnet 7 BRACKET BRACKET esse 00 BRACKET anacker Stay rods and vertical restraint rods for tall outdoor vessels without surrounding structure When tall vessels must be protected against tipping _—_are impractical. use ‘‘vertical restraint rods” (loose- due to wind or seismic forces and safety check rods. _{itting check rods) at the base of the vessel as shown. ‘The vertical restraint rod must not be tightened since this would load the load cell and possibly damage the load cell if overloaded. STAY A008 VESSEL SKIRT LORD CELL AND EXPANSION ASSEMBLIESload cell considerations accessory selection and installation Load and S-cells in tension Tension flexure rods Tension flexure rods are used to suspend weigh vessels from overhead structure. Preferred for heated vessels ‘over compression arrangements since sideloading is, all but eliminated. Chief deterrent is the cost of support structure, which effectively limits cell capacity to ‘50,000 Ibs. A minor consideration is increased vessel displacement and vibration sensitivity due to rod elongation with load, General design rules: 1. Overall length between support surfaces, $ must be larger than either: a. The length which holds the maximum change in initial load/S-cell plumb due to differential thermal expansion between vessel and support structure fo within % degree. (This renders changes in calibration accuracy due to ‘Cosine Error’ trivial.) Calculate this minimum, length as: Smin = 230Ro aT WHERE R = Distance between support point on vessel bracket and centerline of vessel ‘© = Coefficient of thermal expansion of the vessel AT = Max. temperature difference between vessel and supporting structure, usually taken as max. vessel operating tempera- ture less min. ambient tem- perature . The length which from BLH experience, imparts the required degree of flexibility to the tension linkage. $ min ranges trom 20 inches for a 50 lb load/S-cell to 40 inches {for a 50,000 Ib cell EXAMPLE: An eight foot diameter stainless vessel operates al 470° in an ambient environment at 70°F. Taking R tobe about 56”, $250” 2. Optimum load /S-cell placement is midway be- tween support points. Doing this minimizes read- out error due to moments acting across the cell 3. Request BLH Electronics Data Sheet entitled ‘Technical Data for Calculating Rod Lengths (10-063) for detailed instructions and ordering information SUPPORT STRUCTURE DisPLacEMENT @ 7 nin amb INITIAL PLUMB PLANE OF SUPPORT DISPLACEMENT @ Tae vested NOTE: FOR LOWER ACCURACY SYSTEMS 'S MAY BE REDUCED TO 75% OF THE ‘MINIMUM VALUE Errors due to swaying When vessels are suspended, care must be taken that, the amount of swaying is limited. These errors, often ‘small in weigh vessels, can be substantial in crane scales. The error is introduced due to the centrifugal force generated when the weight moves through the bottom ofits arc, similiar to the pendulum in a clock The frequency of the acceleration force is therefore twice the pendulum frequency or where g is the gravity constant. The centrifugal force is proportional to the increase in height of the weight.load cell considerations specific installation procedures Installation sequence for compression load cells @ Preferred method - recommended for High Accuracy Systems Fabricate, or order from BLH Electronics, ‘Simulated Load Calls and Fixed Mounting Plates (or Simulated Load Cells and Expansion Assemblies, Bolt to vessel support bracket. Lower vessel in place and align Using lower Simulated Assembly flange as a template, drill mounting holes in mating support structure, and bolt securely. Install lateral restraints, if required, to maintain vessel alignment for all subsequent operations, Complete vessel fabrication and installation Make all piping connections, weld, insulate, etc. Loosen and remove all lower flange bolts. Using a hydraulic jack, lft vessel " only at each bracket, one at a time. Remove Simulated ‘Assembly; install load cell; shim plumb to within ¥2°; install accessory (bearing plate, expansion assembly base, etc) LOWER VESSEL GENTLY to avoid overload damage to load cell Expansion assemblies for compression load cells Expansion Assemblies accommodate thermal expansion or contraction of a vessel relative to Support siructure with minimum side foading of the load cell. They are generally necessary outdoors when maximum accuracy is desired or indoors when the vessel temperature differs from ambient. An, Expansion Assembly includes a low friction slide plate in the “base assembly’, a “load plate”, and the appropriate load cell mounting screw(s). For details, refer to instructions shipped with unit Load distribution for compression load cells © Shim load cells plumb (first) Stagger shims or shim segments between the oad plate and support, as shown in sketches (at right and on next page). Tighten securely and check that cell is now plumb within %2°. Repeat procedure until plumb. Do not aisturb the load cell thereafter, Repeat load cell installation operation at each bracket Loosen all stay rods to remove any possible restraint, recheck level to within ¥2°, and secure snugtight When done, check load distribution among the cells, shimming if necessary ‘Alternate method - suitable for Lower Accuracy Systems Install lateral restraints, if required. Set level within %°, Bolt load cells in place; visually check load cell plumb, shimming if necessary; install accessory LOWER VESSEL GENTLY onto load cells. Check ioad distribution among cells, shimming as required LonD PLATE |. oan cent cae ousr Boor cAMP BEARING PLATE SUIDE PLATE BASE ASSEMBLYload cell considerations specific installation procedures Load distribution for compression load cells (continued) © Shim for load distribution With full tare weight resting on load cells, measure output of each cell with a readout instrument such as a BLH Model 3528 Transducer Indicator or equivalent. Each cell must indicate some load, preterably not less than 10% of tare weight. It any cell indicates “‘no" output during this test, use a feeler gage to measure gap between load button of cell and bearing plate (or mating accessory), raise vessel, untasten bearing plate, and insert atrial shim having a thickness of 0.015 -0.030 inches plus the gap height. Similarly, if acellindicates “low” output, insert a 0.015-0.030 inch trial shim. Secure bearing plate and GENTLY LOWER weighed structure onto load cells. Since adjustment at one load cell alters load distribution at all support points, ‘measure the output of each load cell again. Repeat this shimming measurement procedure until all load cells read within 20% of each other.system calibration BLH Electronics offers field calibration services as part of its complete weigh system commitment. Field engineers will travel to the site and perform the following operations: © Field calibration procedure Visually check load transducer plumb and ac- cessory installation. Correct if necessary. Visually survey vessel and all attachments for at least ¥%2" clear space all around. Enlarge any tight clearances that have potential for near term, €or long term shifting and mechanical hangup. Measure load distribution on load transducers supporting weigh vessel with a BLH Model 3528 Transducer indicator or equivalent. Shim as required to ensure that the tare weight is distributed on each load transducer to within 10% of each other transducer. (Refer to the Sections on Load Distribution for complete in- structions). Calibrate weigh system electronically using a BLH Model 625 Precision Calibrator or equivalent. Inspect lateral restraint system (stay rods and safety check rods) for proper installation and attached piping for flexibility consistent with required system accuracy. Make recommenda- tions for improved system performance based Upon experience with similar installations When required, arrange for and perform the ‘appropriate mechanical (dead weight) calibration ‘© Electronic - provides calibration accuracy to 0.25% of full scale Compensates for initial load cell installation misalignments such as load cells out of plumb. Does not compensate for any mechanical errors that might arise during vessel operation such as load transducer losing plumb due to beam deflec- tion or twist, nonlinear piping reactions, highly ten- sioned lateral restraints, or thermal expansion Rather, the weigh vessel is assumed to be free trom mechanical restrictions. If attached piping ccan be felt to move under a sharp biow of the fist, the assumption is usually valid. Procedure: One load transducer in the weigh system is electrically replaced with a precise signal from a BLH Model 625 Precision Calibrator. The Calibrator is a device which simulates the output of the load transducer ‘System calibration is then performed with all cables in place, under actual environmental conditions. ‘The Model 625 Calibrator is accurate to within 0.05% of reading, or 0.02% of range, whichever is greater. Mechanical - provides calibration accuracy to botter than 0.25% of full scale depending ‘upon method and care used. Of methods listed below, only Dead Weight and Dead Weight/ Material Substitution are accepted by Weights and Measures Agencies. Compensates for initial load cell misalignments Shows up mechanical errors which may be at least partially compensated for by adjustments within the system instrumentation, Depending upon system accuracy requirements and severity of the problem, mechanical corrections to piping attachments, lateral restraints, ot support structure may have to be performed Usually preceded by electronic substitution to ready system for fine tuning with dead weight Requires use of weight increments of not less than 5% of live load. When certification is necessary, with stringent tolerances given as a percent of test load, increments should n less than 10% of live load Note that span cannot be set with the first increment of weight as for mechanical scales, since a one-count error at 5% of load may be 20 counts out at full load. On lower accuracy systems, span may be set at 25% of load, since maximum error is then only four counts. “Warm Body" method Simplest and quickest to perform. Suitable for calibration of low capacity weigh vessels only: ie., up to about 2,000 ibs. Procedure: Weigh several men on best available scales at hand, e.g., 0.1% shipping room scales, and have them ‘sequentially climb upon weigh vessel Calibrated Material Transfer method Accuracy obtainable strictly dependent upon cate taken in weighing the test material. For example, a tank truck may be weighed empty on a 0.1% truck scale, then filled with test material and reaweighed. But how much gasoline was ‘consumed in the drives between weighing rin the final drive to the site? Did the river stay in the truck during both weighings? How much material was lost inthe transfer from truck to weighCalibrated Material Transfer method (continued) vessel? If a water meter is used, do you believe its reading or recalibrate it on site using a 55 gallon drum and the 0.1%. shipping room scale? Procedure: Add pre-weighed test material (either product or material inert to vessel, such as water, sand or gravel) incrementally to full load. A convenient increment is 10% of load Deadweight method Suitable for high accuracy weigh systems, but limited to vessels of about 12,000 Ibs due to difficulty in obtaining and working with weights larger than 3,000 Ibs Acceptable to Weights & Measures. agencies. Requires some means of attaching certified weights to weigh vessel without damage to vessel or attachments, with out tipping the vessel, and with adequate working room. (Refer to section on Vessel Design for lifting lug suggestions.) Certified weights should be ordered trom a local scale company in increments of at least 5% of live load, preferably 10%. Calibrate weigh system electronically adjusting zero and span to keep tinal adjustment with weights to a minimum Procedure: 1, With vessel in final configuration, including all piping, stay rods, weight lifting equipment such as chain falls, etc, adjust instrument to read zero. 2. Altach first increment of certified ‘weights to vessel making certain there is no mechanical interference with weights and surrounding structure, 3. Note instrument reading. It should agree very nearly with weignts. If error is less than 0.03% of full scale, proceed with next step. If itis greater than 0.03% of full scale, remove weights and re-inspect vessel for ‘mechanical restrictions. 4, Add weight increments until full scale is reached, recording reading at each step. 5. If desired, a span (calibration) correction may be made to the instu- ment at any load point above 25% of system calibration full scale. Ifa large correction is, made, it may be necessary to remove weights and material from within vessel, re-zero instrument, and repeat Steps 2 through 4 so that system linearity is known, 6. After calibration sequence is complete, remove weights from vessel so its in the same configura- tion as Step 1. Instrument reading should return to zero. 7. Detach all dead weight liting gear and zero for last time 8. Inthe unlikely event that noncarrect- able mechanical problems cause linearity to fall outside calibration accuracy specification, some compensation may be effected inside BLH instrumentation. Deadweight/Material Substitution method Suitable for all nigh accuracy weigh systems where it is not possible to use calibrated weights to system full scale Acceptable to Weights & Measures agencies, Obtain certified weights of largest capacity which can be conveniently handled. Ideally, total amount of calibrated weights should not be less than 5% of total system capacity. For example, not less than 5,000 Ibs of weights should be used to calibrate a 100,000 Ib system Asuitable method must be devised to attach weights to vessel keeping in ming that the weights must be removed and re-attached several times during a typical calibration. (Refer to section on Vessel Design for lifting lug suggestions.) Calibrate weigh system electronically, adjusting zero and span to keep final adjustment with weights to a minimum. Procedure: 1. With vessel in final configuration, including all piping, stay rods, weight lifting equipment such as chain falls, etc, adjust instrument to read zero.system calibration Deadweight/ Material Substitution method (continued) 2 Attach certified weights to vessel ‘making certain there is no mechanical interference with weights and surrounding structure. Note instrument reading. It should agree very nearly with weights. If error is less than 0.03% of full scale, proceed with next step. If itis greater than 0.03% of full scale, remove weights and re-inspect the vessel for mechanical restrictions With weights removed add weight into vesse! with whatever compatible material is available (usually water or product) until exact same reading is obtained as with calibrated weights inStep 3, Again attach weights, record reading and remove weights. ‘Add weight into vessel to obtain same reading as in Step 6. Repeat this deadweight/material substitution procedure until desired {ull scale of weigh system is reached 10. " It desired, a span (calibration) correction may be made to the instru ment at any load point above 25% of full scale. Ifa large correction is, made, it may be necessary to remove weights and material trom within vessel, re-zero instrument, and repeat Steps 2 through 7 so that system linearity is known, Alter the calibration sequence is ‘complete, remove weights and all material inside vessel so it isin same configuration as Step 1. Instrument reading should return to zero Detach all dead weight lifting gear and zero for last time. In the unlikely event that noncorrect- able mechanical problems cause linearity to fall outside calibration accuracy specification, some compensation may be effected inside the BLH instrumentation.special design considerations Influence of vessel piping and support deflection Introduction Vessel thermal growth Weigh system problems sometimes arise alter a system Problem - Vessel expands as it comes up to operating has been put into operation. The principal cause of temperature and generates vertical piping these problems are mechanical restrictions to, and restrictions that vary with vessel, pipe, and interaction with, the weigh vessel. The cause is structure temperature. Vessel expansion invariably excessive vessel or support deflections is also restricted when rigid electrical which may have been identified, but assumed to be Conduit used for load cell cable is anchored insignificant, during the design phase, or were so to support structure, or when small obscure that they went undetected. In an effort to Unrelated piping is attached to the weigh censure that BLH Electronics weigh systems function vessel to carty it between floors. properly in al situations and environments, we now resent some of the common and uncornmon deflection Problems that have come to our attention. (The Problems are arranged, not by incidence or severity, but simply from the vessel up) Symptom - Weigh system readout registers a zer0 shift, H vessel operates at several tempera- tures, a different zero will occur for each. lt weighing is performed while vessel is, changing temperature, error is unavoidable Vessel support bracket Remedy -Specity tlexible piping attachments with adequate defiection capability for vessel Problem As live load increases, so does the deflec- Bille (ores ac tion of the vessel wall under the suggort bracket, causing the bracket to til. This Specify tlexible conduit between vessel generates "sideloading” of the load cell by and structure horizontal force components that are now NEVER ATTACH miscellaneous piping, present. Measurable readout error will electrical conduit, etc, to the weigh vessel result if tit angle exceeds %°; potentially for support significant error will result if the angle exceeds 1°. Further, i load cell is mounted on the bracket, a “cosine error" occurs as a function of toad cell inclination trom initial piumb position. ‘Symptom - Weigh system output is increasingly non linear with load. Remedy - Use KIS beams with bearing yokes rather nor ves than canister type load cells. Should the PERIMETER yoke tilt as the vessel load increases, i measurable error will be negligible since 1 the actual force on the beam remains ver- tical. Should the yoke slide slightly, calibration will only degrade .005% tor each millimeter of motion. ‘OF SUPPORT SIDELORD Loaneo vessel onneD VESSELspecial design considerations Influence of vessel piping and support deflection (continued) Tension linkage Problem - Tension flexure rod linkage elongates with load. Vessel thus sinks with load, develop- ing vertical forces in attached piping. (This isa rare problem, only arising when linkage(s) goover 100 inches in the higher capacities.) ‘Symptom - Weigh system output becomes increasingly onlinear with load, Remedy -Keep linkage elongation, & within Ys" under the maximum vessel ive load. Specify flexible piping attachments. LOADED vesseL PERIMETER o=fgraaro(B) Vessel support structure Problem - Large differential motion occurs between vessel support structure and structure Support points of attached piping or stay rods. This is another common oversight made by structural and piping designers who assume the vessel to be stationary in ‘space when in fact the support deflects with live load ‘Symptom - Weigh system output may be excessively nonlinear as large vessel displacement ‘causes mechanical restrictions to develop; .g., attached piping and lateral restraints draw tight and generate vertical forces, or piping installed just clearing adjacent structure now contacts it at increased loads. Remedy. - Follow structural guidance provided in Structural Design section. Make piping attachments flexible. Install KIS beams rather than canister type load cells to eliminate lateral restraints. Support at tached piping from structure supporting the vessel, PREFERRED MOUNT PIPING RESTRAINTS TO SUPPORT STRUCTURE ANO USES BEAMS TO ELIMINATE STAY RODS eer FL00R NOT RECOMMENDED DIFFERENTIAL MOTION GENERATES UNDESIRABLE FORCES Problem - Ail supports, whether exposed beams or conerete floors, deflect with load. A beam, however, will also twist if load is not applied through its shear center. This problem is generally more serious for compression systems than tension systems. ‘Symptom - Nonlinearities will be displayed in weigh system output as beam deflections give rise to unpredictable load cell alignments These, in tum, incur variable cosine errors and sideload forces in compression installa- tions and cause high bending moments in ends of tension flexure rods,special design considerations Influence of vessel piping and support deflection (continued) Vessel support structure (continued) Remedy Problem Align load transducers with shear center of support beam; preferably, only symmetric ‘I or ‘WF’ -beams will be used whose shear eFLects a 7] 1 Vessel natural frequency, , decreases with nereasing structural detection. 8 according toe formula, nt _ where! equals te force of gravity (0.81 mis of 386in is) itlarge support deflection occurs. the vessel may osclaten response to nearby tafe (ain truck, fort. crane. oust people}, process equipment (oumps,agita- tors, diesel engines, cyclone devices et) internal events (Hud sloshing, chemical reactions), or wind Structural fatigue must now be a consideration as well, Good design practice avoids natural frequencies below 4 Fzin general 8 Heit compressor isin the system center lies on an axis of symmetry. Refer to “Structural Design’ section for additional details € wes € ¢ a | Es i > + veriecrs st ¢ 9 y os + + — $= : ye mst uanae Bes Symptom - Weigh system output oscilates, either randomiy or periodclly. to one of many ampitudes, Remedy -For small oscillations, election titering is available for most instrumentation. Addi: tional filtering is possible for large oscilla- tions by addition of large values of capacit- ance across load cell output - Stiffen support structure, curtail or isolate ‘as much of causative activity as possible. or schedule weigh vessel operation for low activity periods. -When high frequency forces are present, consider isolating the vibration source from the structure.special design considerations Influence of vessel piping and support deflection (continued) Vessel support structure (continued) woo) - T TT TTTT T TT TTT 7 of 4 so 4 sol 4 30 Feo 3 a Zo 4 BE q gs ab 3 2 ish J 1 ju Liit 1 41 siti 0.08805 igs 28 BS 2s (uM) oor (808 30s 81080 os To Uwenes) DEFLECTION 6 GROSS VESSEL WEIGHT SUPPORT DEFLECTIONspecial design considerations Influence of vessel piping and support detlection (continued) Vessel support structure (continued) The use of vibration mounts under the Further, the added displacement may weigh vessel is not recommended since require reworking of external restraints, this will increase deflection and lower the and attached piping natural frequency. ISOLATE EOUIPMENT FROM FLOOR \WiTu VIBRATION moUNTS ‘oo STauCTURAL STIFFENERS, Piping thermal growth Problem - Piping expands from fixed support to vessel attachment as hot fluid passes through. It pipe has a vertical leg between support ‘Sympiom - Weigh system zero shifts as pipe discharges hot contents then cools to ambient again, medy - Attach fixed pipe support ac vessel and vessel, avericalorce may beimpartea ‘Remedy. tach tixed pipe support agjacont to vessel to vessel: if pipe has a major horizontal eR eee ee run, it may generate enough over-turnin, imposed upon weigh vessel, Specity flexible Geeieined ei clgh vesee| Seae piping attachments or provide expansion pore eet eee oops in pipe betweer it and vessel even lifting a vessel bracket off of the load ata eerie ocenr nee transducer FLooR ABOVE j > EXPANDS HOM THIS POINTInfluence of vessel piping and support deflection (continued) Piping support deflection Problem -Pipe supports, especially the first supports away from vessel, defiect under random influences, generating vertical pipe forces on weigh vessel. This is, perhaps, the most ‘common problem encountered in the field. ROOF DEFLECTION WITH CHANGEIN ‘OUTDOOR TEMPERATURE ROOF ¢ ‘ROOF DEFLECTION sRDER VARIES WITH THE ELEMENTS wei vEsseL ‘Symptom - Weigh system zero shilts randomly Remedy - Attach first pipe to same structure weigh vessel rests upon. Specify tlexible pipe attachments, PRECAST CONCRETE ROOF eich vesset meee AL ‘UNWEIGHED VESSEL FORKUFT ¥ FLOOR DEFLECTION DUETO CHANGE IN ‘CONTENTS OF UNWEIGHED VESSEL, FORKLIFT OR ‘OTHER TRAFFICspecial design considerations Influence of vessel piping and support deflection (continued) Vessel interaction Problem - Weigh vessel support structure loses initial known to be constant level and tilts as a function of another vessel on same floor. While angle ot weigh PeENY ~ Seana auccnments, Suppor vessel may be small, net displacement at ore s point of pipe attachments may be large, introducing multiple pipe forces. Further, ~ Convert partially supported weigh vessel if weigh vessel is only partially supported so that itis fully supported by load trans- onload transducers aor tit may upset load ducers and floor tits less important. A less fraction seen by load transducers if trans- effective fix is to reposition the existing load ducer alignment is not toward other vessel. transducers to line up toward the chief source of floor deflection and then observe center-of-gravity shitt, at least partially Symptom - Weigh system output inexplicably shifts even though weigh vessel contents are ‘SMALL ANGLE = LARGE DISPLACEMENT e/ ‘nwercieD VESSEL sure ‘a res ‘WHENEVER UNWEIGHED ‘VESSEL LOADS UP FOR PARTIALLY - SUPPORTED VESSEL. ALIGN LOAD CELL [ITH DEFLECTION SOURCE ea 1010 ceus © BEAMS ‘BEAMS CELLS. 7 ul DEFLECTION 7 4 ‘SOURCE v) \> ‘VESSEL y > TAN TANGENT ONLY ue ce srs wr icon none ur DESTHOTM CALBNATION tom ono cats cats : ous oeriseron aie SOURCE o~ 0 beams ! igh co SHIFTS, BUT CHANGE IN Mass CENTER IS SEEN BY THE LORD CELLSspecial design considerations Influence of vessel piping and support deflection (continued) Vessel interaction (continued) Common Problem -Weigh vessels alignedin a row are BEAM supported such that adjacent vessels each e yo have a load transducer resting on a At ‘common support beam. If one vessel is. then heavily loaded while adjacent vessel remains lightly loaded, lighter vessel may lose support from the now-deflected y common beam, The resultant gap between load transducer and vessel bracket not only CS Nullfies vessel calibration, but allows vessel cans torock l essen i NEAREMPTY =) ‘Symptom - Weigh system output changes and may oscillate although no change in contents has occurred as one load transducer gaps and vessel rocks. Remedy - Use three-point supports to eliminate possibilty of gapping. Donot use a common support member between two adjacent vessels. See Structural Design section for preferred vessel support arrangements, BEAM DEFLECTS. WITH LonD IN #2 Problem - Separate weigh vessels are connected to ‘weight increase in the other vessel for ‘common run of pipe. Although flexible the duration of the operation connections are provided, the pipe is still partially supported by both vessels. Thus, in the example shown, a drain operation from one vessel causes an apparent ‘Symptom - Output of one vessel shifts with operations at connected vessel NOWMETALLIC vawe FLOATING COMMON PIPE ‘Nor RECOMMENDEDspecial design considerations Influence of vessel piping and support deflection (continued) Vessel interaction (continued) Remedy - Isolate common piping with supports independent of both vessels. PIPE SUPPORTS. PREFERRED Outdoor installations © Rigid vessel support foundations are essential. Foundations that heave, sink, or otherwise shift with time alter the initial level of the vessel and. thus, the support reactions seen by the load transducers. © Consider a shelter for the vessel when system accuracy better than "4% is required and when, high wind, snow, or ice conditions are prevalent, ‘Snow andice alter the vessel tare weight while wind forces may impose positive or negative lift on the vessel; all unpredictaoly. © Piping expansion loops or flexible piping connections are essential to accommodate differential thermal expansion between vessel, piping, and piping support structure, and to allow unrestricted deflection of load transducers, © Platforms and ladders attached to a weigh vessel should be totally supported either by surrounding structure or foundation, or by weigh vessel alone. Contact with any other vessel, structure, or foundation can couple the weigh vessel to it causing unpredictable readout errors. © Atree-standing blind of sheet metal or a wrap of thermal insulation is advisable for load trans- ‘ducers directly subjected to radiant heat or wind chill. The nonuniform thermal gradients Produced in the load transducer by these en- vironmental effects cause temporary zero shifts in load transducer outputs. Arc welding on a weigh vessel © THE DAMAGE MECHANISM IS HEAT, Welding ‘can damage a load transducer only if welding current passes through the transducer; induced voltage will not harm the load transducer. When several hundred amps pass through the steel element of a load transducer, resistance (/°A) heating occurs. Should the element tem- perature exceed several hundred degrees Fahrenheit, the adhesive that bonds the strain gages to the element will begin to decompose. In short, welding across a load transducer will very likely cause irreparable damage to the unit. © ARC WELDING PRECAUTIONS: Betore load transducer installation. Perform as much vessel fabrication as possible prior to load transducer installation. Use simulated load cells or dummy beams during vessel construction. See Accessory sections for installation detall Atter load transducer installation. Attach the welder ground lead directly to vessel, preferably adjacent to weld site. When this is,special design considerations Arc welding on a weigh vessel (continued) ‘not possible, put high-current-capacity cables Where routine welding maintenance is anticipated, ‘across each load transducer to ground vessel to permanent ground cables are advised. Braided: structure. DO NOT rely on stay rods or piping ‘copper automotive ground straps are suitable for for grounding; rods generally have high resistance this purpose. terminations, while the piping may contain non- conductive flexible couplings, Technical data for calculating rod lengths Request BLH Document - TECHNICAL DATA/Tension Flexure Rods (TD 063) Sizing of lateral restraints Request BLH Document - TECHNICAL DATAVSizing of Lateral Restraints (TD 068)Piping flexibility Introduction ‘Aweigh vessel, without any mechanical attachments, fully supported by load transducers mounted on a firm base will demonstrate a system accuracy approach- ing that of load transducer and instrumentation alone, a value well below 0.1%, If lateral restraints are now added in the form of stay rods attached to nearby floor brackets, system accuracy should remain undisturbed, provided that installation rules are observed. A similar statement can be made for vented weigh vessels since inlet and outlet piping need not contact vessel; simply pass inlet piping through an oversize clearance hole in the top of the vessel (when there is an upper surface) and let outlet piping lead into a funnel arrangement underneath. Details are presented in the section titled ‘Piping Design. When problems do arise, they generally involve sealed systems requiring piping to be attached directly to vessel. Here piping is an active part of the weigh ‘system; any motion of the vessel relative to piping and vice versa will generate vertical and horizontal reaction forces on the weigh vessel. Rules governing the magnitudes of these forces are the subject of this section. Design criteria The total vertical force, V, generated by the deflection ofall piping attached to a weigh vessel should not exceed a percentage of the maximum live load, L, proportional tothe required weigh system accuracy, A V (OAL where: A = system accuracy, inpercent Hence, for a0.1% system, V < 1.0%L; for a 0.25% system,V <2.5%L; for a0.5% system, V <5.0%L; for a 1.0% system, V $10.0%L. This fotal vertical piping force represents the sum of individual vertical piping reactions, Pi, generated by differential motion between pipe anchorages (ie., the point of attachment on vessel and first pipe suppor!) and by thermal expansion in vertical segments of pipe located between anchorages. These forces often can and should be minimized by mounting first pipe support to vessel support structure and using only horizontal piping runs between vessel and first pipe support. special design considerations The force criterion is intended to maintain highly linear piping response suitable for the most accurate weigh systems, yet permit increasing amounts of nonlinear forces to develop without impairing the required weigh system accuracy. It follows that more care and expense is required for he design and installation of piping on a high accuracy vessel than for a low accuracy vessel. The total vertical deflection, v, to be evaluated for each run of pipe attached to a weigh vessel is equal to the algebraic sum of all imposed deflections. ive s+ dwt spt ba where: $5 = vessel support deflection Btv = vessel thermal expansion to point of pipe attachment (e.g... nozzle or flange) 8tp = pipe thermal expansion in vertical runs of pipe leflection of first pipe support or anchorage, a value often independent of vessel support structure Deflections tending to increase indicated vessel weight are given positive signs, and vice versa ba \When several combinations of deflections are possible, determine which is the limiting condition and base the piping design on it. For example, a weigh vessel on one floor may be directly attached to a storage vessel on floor above as illustrated in Figure 1. Assume there is no other attached piping present. If weigh vessel is {ully loaded when storage vessel is empty, 8a = 0, but, 88(and thus & v) may be —055 inch (12.7 mm). At some later time, the storage vessel may be filled Causing an anchor motion of, say 0.25 inch, so that 8a = +0.25 inch (6.35 mm)and &v = —0.25 inch For this simplistic example, the limiting case is when the weigh vessel alone is fully loaded. The minimum vertical deflection, 6 v. tobe applied to any pipe is ~ 0.100 inch (~2.54 mm). Use this value whenever more significant deflections cannot be identified itis intended to cover the dimensional change of load transducer under live load — generally under 0.010 inch 254 mm), as well as a modest amount of Cold-springing required for initial pipe alignment.special design considerations Piping flexibility (continued) Design criteria (continued) ‘Amore common situation is that of a weigh vessel supported from a building floor or stee! framework, ‘Such vessel support structures generally exhibit maximum vertical deflections of 0.25 inch (6.35 mm) 10 0.50 inch (12.7 mm) under gross vessel weight, although some installations have deflections aporoach- ing 0.75 inch (19.05 mm). Ifa realistic evaluation can bbe performed for the maximum vessel support deflec- tion, let 6 s be the resulting value. Otherwise, take bs = 0.50 inch asa reasonable estimate. Vessel thermal expansion, 6 tv, is determined trom the expression dw=LeatT distance between vessel piane of support and pipe attachment point = coefficient of thermal expansion, with max. values of 9.6 x 10%/°F (1.7 x 10°/°C) for stainless steel and 8.4 x 10°/°F (1.5.x 1071°C) for carbon ste! AT = maximum vessel operating tempera: ture minus ambient temperature. Pipe thermal expansion. 6 tp. is evaluated as indicated above except that Lis now defined as the sum of the lengths of vertical pipe segments between weigh where: L meer PLANE OF vessel and first pipe support. This parameter may be ignored when pipe expansion is below 0,050 inch (1.27 mm), Pipe anchor deflection, 6 a, isa significant factor in weigh system performance. Refer to the sources of floor deflections in section entitled, “Special Design Considerations” before assigning a value. NOTE: Itremains the responsibility of the vessel or pipe designer to ensure that the level of stresses in piping, vessel attachments, and pipe supports is in accordance with applicable piping and vessel design codes, Itis also incumbent upon the designer 10 ensure that forces and moments imposed.on associated pracess equipment by vessel piping are within limits specified by equip- ment manufacturer, DISCUSSION OF DESIGN CRITERIA- In applying the vertical force rule, the piping designer must assign realistic values of deflection to each piping run attached to the vessel. This means that vessel support deflec- tion, vessel thermal expansion, pipe support deflection, and pipe thermal expansion should be considered, ra STORAGE VESSEL PaEFERRED SUPPORT ba~ 5820 ono i VESSEL SUPPORT STRUCTURE alam AT THE INLET, {3 50.1 inh or preted support VS — }8e:§ afornox Mao spon ATTHE OUTLET, By =~ 0.1 inch as shown ourier F + ba- smoPiping flexibility (continued) Design criteria (continued) DISCUSSION OF DESIGN CRITERIA (continued) For example, the vessel at constant ambient tempera: ture shown on the previous page generates a vertical pipe reaction at the inlet as vessel support structure deflects an amount 85 that varies with load; significant pipe forces are precluded at vessel outlet by attaching first pipe support to vessel support structure, thereby minimizing differential motion between pipe and vessel For this case, itis obviously beneficial to support all piping from vessel support structure so that attached piping moves only with vessel, isolating weigh system from motion of other floors and equipment. Whatever forces do develop are primarily due to installation fitup and are essentially constant, contributing only to vessel tare weight, Design the piping runs from vessel to first supports with sufficient flexibility to meet vertical force criterion PLANE OF SUPPORT special design considerations consistent with system accuracy required Let the vessel now operate at some constant tempera ture above ambient. As indicated below, vessel thermal growth affects both inlet and outlet piping, Estimate vessel expansion at each end of vessel from bw=LaaT as previously discussed. Vertical displacements at both inlet and outlet are the algebraic sum of: bv= b+ bs4 ba Itis again beneficial to support all piping from the vessel support structure to achieve weigh system isolation. In fact, the only difference between this, case and the first is the need for additional flexibility of each piping run to assure a linear response to vessel deflection with load in spite of imposed thermal expansion Pie ANCHOR TP +b bax0 PREFERRED I~ PIPE SUPPORT (OELETE ANCHOR) Courter ‘AT THE INLET, GY + Sivtorpe v4 bv ~ Bs ‘ATTHE OUTLET, (V5 — 51V8 shown ed support ‘5 Tor ex tor suppert { I> + 50-50special design considerations Piping flexibility (continued) Design criteria (continued) DISCUSSION OF LATERAL PIPING FORCES- Lateral piping forces are seldom significant for weigh vessels, fully supported on load transducers: the requirement for vertical flexibilty automatically imparts a degree of lateral flexibility to attached piping; the lateral force resultant is reacted by the lateral restraints; and the net overturning moment, while partially unloading a load transducer(s) on one side of the vessel, merely adds load onto load transducer(s) on the other side without a change in indicated vessel weight. Rarely is the overturning moment large enough to actually lift the vessel and cause gapping to occur between load transducer and vessel. Lateral piping forces are more likely to cause problems for weigh vessels partially supported on load trans- ducers since any overturning moment that arises is likely to alter the weigh system output. Refer to the ‘Piping Design’ section for suggestions on minimizing piping influence, Design analysis for piping INTRODUCTORY COMMENTS - The information presented herein will enable the reader to estimate the total vertical piping force acting on a vessel. If this resultant force exceeds live load criterion, action should be taken to introduce additional flexibility into the piping system. This may be accomplished, for ‘example, by increasing the horizontal length of piping between vessel and first pipe support, redesigning attached piping to include a right angle segment or ‘expansion loop, inserting a flexible device, or specitying allighter schedule pipe. Refer to "Piping Design” section for suggestions. Specific designs for piping cannot be pre-engineered {or limiting cases and presented in design charts, as for stay rods. There are few, ifany, ‘standard’ piping configurations, Identical vessels installed in different buildings will still require customized piping runs to accommodate changes in floor height and stiffness or associated equipment. Hence, the piping design analysis is necessarily lettin basic form. ‘Two figures presented in this section show pipe spring rate as a function of span length for Schedule 40 pipe and, a more general chart, spring rate as a function of span length and pipe moment-of-inertia. These figures yield conservative, high-side values for spring rate that may be moditied by factors derived below. PIPING FLEXIBILITY OVERVIEW - The vertical reaction force, Pi, developed in one straight span of pipe in response to differential vertical motion, vi, between fixed end points is: Pi = Ki 3vi where: Ki = sorina rate. or pine stittness For all piping attached to a weigh vessel, the summa- tion of individual pipe reactions, Pi, should meet the vertical torce criterion Ki dvi] < (108) ‘A = system required accuracy, in percent L = maximum live load. where: The points discussed hereatter are intended to aid in estimation of overall vertical piping forces acting ona weigh vessel as piping layout is being generated. More accurate force values, when warranted, may be obtained by using computer programs specifically written for piping analyses. SPRING RATE, K-As indicated above, the stiffness of a pipe fixed at one end against all deflection and rota tion, and guided at the other is given as: Ka 126 rn The valu eprooams an per bound tat isnot detievabe because inherent Hanoi vee nozrloo, lenges ot wale andotine pape eamor The Dorp nda ecogtsu sand gasecly oe k= 1961 ferent ere ees erect fixed ends (above) and K = 8EI for abeam simply supported at both ends*. P “MW. Kellogg Company, Design OF Piping Systems, nd Eton, John Wiley & Sans, pg. 290Piping flexibility (continued) Design analysis for piping (continued) SPRING RATE, K (continued) The spring rate developed in the charts on the next two pages are based upon the theoretical fixed end condition with an additional design factor of two applied. For this analysis, these spring rates should bbe derated by a ratio of /10\\ or 0.42 24 Thus, the corrected vertical force equation should read, P = 0.42K 6 v, where K is read directly from the Figures. NOTE: Etfective length for a nonhorizontal pipe ‘span is equal to its projected length on the horizontal plane; | = L cos A. A vertical run of pipe has zero span length, and may be Considered to have infinite stiffness for the Purposes of this analysis. cass secTion ‘AREA. Kaciat >> TYPICAL K uaTenaL AE 5, WET oe FLEXIBILITY TRENDS - To increase the flexibility of a straight run of pipe, add a horizontal leg at right angles. ‘The straight run now benefits from both bending and torsional deflection of the leg, For example, consider a pipe span, cantilevered from a “rigid” anchor, with an enforced deflection, Yat the free end. The vertical reaction, Wo is: Wo (8 y a special design considerations Haight angle ot length bis now add the reaction becomes we (Lote) ¥,0r86% Wo when = 2a 2 wa(2) Y,07 33% Wo whenb = 5a El & (EX)y 017% Wownend = w () jowhenb =a VERTICAL LEG iio anchon FINAL VERTICAL FORCE EQUATIONS - Assuming these trends to hold for the fixed-guided condition and rounding up for a modest element of conservatism, the pipe reaction force, P, becomes P = 0.5K dv fora straight run of pipe P 0.3K By fora right angle bendwithb = .2a P 0.2K Sylora right angle bend withb = Sa P 0.1K bvfora right angle bend withb = a where Kis read directly from Figures 4 and 5. It should be understood that these equations are not exact, but are adequate for estimating the vertical piping forces for comparison with the empirical design criterionspecial design considerations Piping flexibility (continued) Design analysis for piping (continued) SPRING RATE (1W/in) ° fai 122 Les 2aq 308 3.6827. were 2 ay te 3) wo) “ad ay een) SPRING RATES FOR SCHEDULE 40 STEEL PIPE NOTE: Spring rate obtained tom the above char should be decated by 0.42. (tar section on Spring Rte)special design considerations Piping flexibility (continued) Design analysis for piping (continued) 3 5 ‘SPRING RATES FOR STEEL PIPE NOTE: Spring rate obtained tram the above chart shouldbe derated by 0.42 (fart section on Sing Rate)special design considerations Piping flexibility (continued) Stiffness of flexible piping devices ‘A misconception regarding flexible devices such as, ‘expansion joints and flexible couplings is that, once installed, they accommodate all motions imposed upon them without significant force reactions. That this is generally untrue is shown in Table 1, where preclude the use of much longer offset piping runs, Itis incumbent upon the piping designer to request applicable stifiness data trom the manufacturer of the flexible fitting prior to finalizing his piping layout, several different piping layouts are compared, leading (2) Lighter schedule stainless stee! piping (e.g Caen eee eee schedules 10S and 5) otter significant improve- (1) The use of horizontally-positioned universal joints ments in flexibility over the standard heavier is recommended whenever spacial requirements schedule carbon steel piping commonly used Vertical reaction forces generated by a 0.25 inch (6.35 mm) end deflection NOMINAL] —STEEL PPE PIPE SIZE | Sen 0 Sen 108 imme.) | eg | 70) ra20 | 325 | 204 a00_| 75 | 350 3nua0 [050 | 1.78 ‘z00-_[75,000| 32300 NOMINAL] STEEL PIPE ‘Pe Size | sen sen 108 (rnin) |g | ag) 7620 | 65 300 | 185 se0 15.000 EXPANSION JOINT VERTICAL womuwL) Tee] MiMuW—(]TEFLON VERTICAL oma. | gt) | mmvina | eg) 10 rg : 2 connvcarions pegs | ara geez — v4.00 | so | 7.875 au woRZONTAL EXPANSION JOINT! HORIZONTAL U wwimum -U) STEEL [wmniMuM 1) TEFLON (om/iny [g/t] ming | g/t) 2 g2.10- | 47.70 am see | “Tos wT 356 200 [34 400 nar | 250 TABLE 1Piping flexibility (continued) Vertical reaction forces generated by a 0.25 inch (6.35 mm) end deflection (continued) UumivensaL som MouMuM Mf STEEL] TEFLON tevin fiegrt| g/t) 509 182 ana 4 383 Bi mas 18 special design considerations HORIZONTAL TABLE 1 NOTES. (1) Steel expansion joint data is from Badger Expansion Joint Company, New Castle, Pa Catalog 738; Telfon expansion joint data is from Peabody Dore Corporation, Houston, Tx., Data Sheet 8RO6 and Peabody Dore Drawing A-37858, Table of Spring Forces”. These steel joints are rated at 300 and 400 psi: the molded Tetlon joints, at 150 psi (2) Universal joints comprise two expansion joints and an intermediate length of pipe. Teflon joints are custom items from the vendor, so data is not readily available, For comparison purposes, the same percent force reduction given for the stee! joint was applied to the Teflon joint Expansion joints and flexible couplings are made with a variety of materials, material thickness and dimensions to suit specitic applications: for example, units with lower pressure ratings and greater numbers of corrugations would generate lower forces than those presented. here. When inquiring of a manufacturer, stipulate the maximum stiffness required and the space available in addition to the usual information. (4) Atiexible device installed vertically develops vertical thrust forces with the onset of vessel pressure associated wilh material flow and some. chemical reactions, The magnitude of these forces, V, is given by V = AP, where Ais the ‘mean internal area of the device and P is the estimated pressure, This is one reason why such devices are best installed in the horizontal runs adjacent to @ high accuracy weigh vessel ILLUSTRATE PROBLEM... PIPING FLEXIBILITY Given’ The weigh system shown, tis an existing vessel to be retrofitted. The attached Piping is schedule 40 steel except for the universal joint. An accuracy of 0.1% is required over the maximum live load, L of 45,000 Ib (20430 kg). The vesse! is at constant ambient temperature. All pipe anchorages are assumed to be nondeflecting. The maximum vessel support deflection is estimated to be 0.25 inch (6.35 mm) Discussion: Since no vessel thermal expansion ‘occurs and all pipe anchors are rigid, the vertical detlection imposed on each of the pipes is the same; that is, 8V = —0.25inch 6° ws Us & be — = TREE 1004N | TARE 10,000 RISBEAMS | LIVE45,000 as J UNIVERSAL Join Ke A i Ps peso =x | “PSR IAS hwo eeespecial design considerations Piping flexibility (continued) ILLUSTRATE PROBLEM... PIPING FLEXIBILITY (continued) Procedure! (1). Total vertical force ~ the absolute value of the total piping force permitted for this installation is: V = 10AL = 10(0.1%)L = 1.0%L V = 0.01(45,000) = 450 Ib (204 kg) (2) Piping stittness, K Determine the appropriate pipe stiffnesses for the 4, 6, and &:inch lines from Figure 4: (4ineh, 10 ft, long) K, = 3.0 x 10° Ibtin (inch, 81. long) K, = 2.3% 10" in (inch, 8 tt. long) K, = 5.8.x 10¢ Blin The lateral stitiness of the 1 2sinch universal joint must be obtained from the manulacturer. For this problem, let K, = 175 lblin. This assumes that the right side of the joint is to be fixed, with- out any allowance for the tlexibilty of the piping beyond that point (3) Vertical pipe reactions, Pj ‘Since each pipe has only a straight horizontal run, the applicable equation is: P = 05K 5V Thus, 0.5(3x 10)(-0.25) = -375 Ib 0.5 (2.3 x 109}(—0.25) = —2875 Ib 0.5 (5.8 x 109}(—0.25) = ~7250 Ib 75(—0.25) 45 Ib = 13545 Ib Howover,V =|2P)|= 1954510 >> 450 1b permitted for this installation Discussion: Clearly 6-and 8.inch lines reauire redesign for a 0.1% system. Possible solutions are tor (a) put expansion loops in both lines, (b) change the straight spans to schedule 10S stainless, process permitting, or (c)_ insert additional universal joints. ‘The first solution, (2), requires piping analysis beyond the scope of this manual. Solution (b) doesn't appear fruitful since the data in Table 1 suggests a decrease in pipe reaction of only 2 or 3 times, whereas a factor of at least 6 is required here. So, for this example, additional universal joints will be inserted. (4) Universal joint stiffness ‘One manufacturer specifies the lateral stitfness. for 3 corrugation metal universal joints with 300 psi ratings at Kye 40 Ibfin, (overall length < 43inch) Kyr= 70 Ib/in. (overall length < 46 inch) (5) Vertical pipe reactions (2nd try) P, = 375 Ib Pp= Kay = 40(-0.25)= —10 lb Ky = 70(-0.25) = 201 =45 Ib Pi = 45015 V = 450 Ib = 450 Ib The insertion of two standard universal joints in the 6- and &:inch lines eliminates all possibility of nonlinear piping response on this weigh system. Discussion:Support deflection UNDER GROSS VESSEL WEIGHT- © Vessel support bracket should not tilt more than %° © Vessel support structure should deflect uniformly, generally less than ¥ inch (12.70 mm) © Vessel support plane should not tilt more than Y¥2° due to any external event © Load transducer support beam should not twist or warp more than 4° vesset supront| BRACKET oan ceut pene ot PLANE OF SUPPORT VESSEL SUPPORT ‘STRUCTURE ‘SUPPORT DEFLECTION SHOULD BE THE SAME AT ALL SUPPORT LOCATIONS System accuracy may be compromised by: © Nonlinear mechanical restrictions if a vessel =tilts with increasing load + rocks with agitation or chemical reaction Ee igh WRONG ‘UNIFORM DEFLECTION, VESSEL STAYS PLUMB, VESSELTILTS: structural design ‘SUPPORT DEFLECTION SHOULD BE LESS THAN 2 INCH (12.70 MM) UNDER GROSS VESSEL WEIGHT ‘System accuracy may be compromised by. © Nonlinear mechanical restrictions when differential motions between vessel and piping or lateral restraint supports exceed design estimates © Excessive vessel motion if “soft” support puts system resonance near frequency of pumps, agitators, traffic, wind gusts, or violent internal chemical reactions, THE VESSEL SUPPORT PLANE SHOULD NOT TILT, MORE THAN ¥° IN RESPONSE TO. © Temporary events (forklift traffic, level changes in nearby vessels, etc) weish sronage a al a VESSEL / DEFLECTED FLOOR PROFILEstructural design it it Tilting of the support plane causes a ‘cosine error’ in Support deflection (continued) theloodansdce's nner sgnls ecteseby THE VESSEL SUPPORT PLANE SHOULD NOTTILT _‘Te0s being the il angle. The readout indicates MORE THAN '"IN RESPONSE TO. less materia thanisacualyin he vessel. iting likely to create unanticipated mechanical restrictions as attached piping is displaced laterally by the vessel. HEAVY EQUIPMENT ALTERS FLOOR PROFILE © Permanent events were A vesse. by ‘ORIGINAL WEIGH VESSEL POSITION AST Top wane Soo SSS ru owunuranw F.oon INSTALLATION oF neavy SETTLEMENT Queer eas LATER Load transducer/support beam alignment ALIGN LOAD CELL WITH BEAM CENTERLINE TO SYSTEM CALIBRATION ACCURACY IS NOT COM- AVOID TWISTING OF BEAM WITH LOAD, SOTHAT PROMISED. nigwr ons ¢ : sic wows € g w w +— suséers p< FLEXURE OD Gussers —— Cob «bofstructural design Diagonal beam support LOCATE LOAD TRANSDUCERS CLOSE TO VERTICAL COLUMNS TO MINIMIZE SUPPORT DEFLECTION AND TILTING OF THE LOAD TRANSDUCER DUE TO. SIDELOADS PREFERRED INSTALLATION ‘STIFF SUPPORT FRAME EMPLOYING DIAGONAL ‘SUPPORT BEAM ALTERNATE GREATER VERTICAL AND ORIZONTAL DEFLECTION FOR EQUAL BEAM SIZE n DIAGONAL SUPPORT BEAM C . DETAIL 7 > VERTICAL COLUMN oa i 7 i MAIN FRAME. od 1 GIRDER 1 Up osama | |} supeonr Torsion ‘BRACE: (WELDED, 4 Typ) 1S BEAM PLUMEstructural design Diagonal beam support (continued) PERFERRED ARRANGEMENT © Provide above floor access to facilitate load tran- sducer installation © Vessel weight carried sately in compression, not shear. Lateral restraint brackets may fit directly on the beam as well (Lateral restraints are usually not necessary for KIS beam installations) | [—— sour et weLo Vessel interaction When weighing adjacent vessels, structurally isolate ‘one from the other to minimize cross-talk or interaction DIAGONAL SUPPORT BEAM esse BRACKET ES mnths SY BEAM between them. Otherwise, weight changes in one vessel will afect the readout of the adjacent vessel. ‘COMMON HORIZONTAL BEAM ile Ey e NEXT BEST LESSER ALTERNATE GIO PIERS OW AFRM SEPARATE SUPPORT FRAME TWO VESSELS HAVE COMMON FOUNDATION FOR EACH VESSEL, ALL BEAMS SUPPORT MEMBER ‘SAME SIZE AND LENGTHstructural design Vessel interaction (continued) PossiBluTY OF GaPPIG EXIST ) 7 SEGSea TESS ALTERNATE ISSO ‘Ato sears nue, faces iene = Pelle Suma wees ona Ta. oe WHEN OTHER VESSEL LOADS UP Stiffening existing structures Excessive support structure deflections are undesir able for many reasons. (Refer to Vessel, Piping, and ‘Support Deflections). Should it become necessary 10 stiffen an existing vessel support structure, the following suggestions may be of interest —~ ~——— 1 Wf fH Gt # Dertecreo PROFILE ‘COMPRESSION MEMBERS (Structural Tubing) FERS ron tans FORM suPPo “AROUND VESSEL, BUT REMEDY #1 MIOSPAN DEFLECTION ISuARGE 16"structural design Stiffening existing structures (continued) ~ nt awe H u N awe (| wr E = ic 5 LE cowPnession ewe suPront MEMBERS Le “eat em SITUATION #2 SUPPORT BEAMS NOT untronm, vessec necks ‘on ier Beams FES g ISS (SITUATION #1) REMEDY #2 existing we We ane \ q a UF USE LARGEST PossiBLeFLLET t WELD: CONTINUOUS FOR FIRST } FOOT AT OTH ENDS INTERMITTENT awe “THEREAFTER. CALCULATE SHEAR New ewe wiTa wioeR ‘STRESSES AT WELO FIRST TO FLANGE TO FACILITATE ENSURE FEASIBILITY FOR WELDING APPLICATION REMEDY #1 reer REMEDY #2 REPLACE SWF BEAMS WELO ANOTHER BEAM ‘WITH STIFF 14WF UNDER EACH EXISTING ‘SWF BEAMstructural design pournor details - KIS beams Retainer yoke assembly bolts directly to vessel © Vertical restraint rods typically not necessary support bracket © Provision for jacking (simplifies installation. Stay rods typically not necessary maintenance and field calibration) STFFENER Fy VESSEL SUPPORT \ BRACKET STIFFENERS ctanen yore | | (OP70"AL) ate = = FS Pontate nyorauuic = JACK xis aEAM \ ‘SHIM(s) FOR SETTING IS BEAM PLUMB, Support details - compression load cells Preferred stay rod arrangement © Vertical restraint rod (used when safety check Provision for jacking (simplifies installat maintenance, and field calibration) TIFFENER aun sure TAY RoDs \ — a ra rods cannot be installed at other elevations) STIFFENERS. roPTionaL) L OVERSIZE CLEARANCE HOLECTYD) il oa sum one sean uate sieht 1 noses bu ye) snoxmust8¢ conte. ind iol oii _4_-vonraste nvonavuic MAR vena ester — Yan = {} Sune orev un tb oat rare ‘hums FoR SerTING {OAD CELL PLUMB ee j>— ausserstructural design Support details - tension load or S-cells ‘THE CHECK ROD ALSO SERVES AS- AN INSTALLATION TOOL: © Hang vessel on check rods at proper height, © Make all piping connections, weld, insulate, etc © Install tension cells and flexure rods, set plumb © Back off nuts on check rod so tension cells support vessel © Set gap on check rods and lock up nuts VESSEL WALL SAFETY CHECK c STIFFENER ASERVICE TOOL © Check rods canbe again used for vessel FFASION. support oo STAY 8ODS OR CHECK RODS should vessel need repairs or modifica- (When Required tons (protect tension cells trom mechan ical impact) ~, -should tension cals ever need repairs 3 ‘SUGGESTED ROD ARRANGEMENT SPHERICAL Leven to wirhin ‘CLEARANCE HOLE Wi vr) [— riers no No conTaCT Puma To esse LeveL TO l wirain Nocontacr (777M |W SPHERICAL 5 WASHER TENSION FLEXURE ROD SAFETY CHECK RODstructural design Hydraulic calibration arrangement PREFERRED TECHNIQUE: Calibration unit removes live load from perma- nent load transducer © Operating procedure Zero both systems Fill vessel to capacity with product. Jack calibration cylinder untilit carries 80% of gross weight or maximum live load. (This limit prevents gapping on the permanent load transducer.) Bloed oylinder to reduce load on ealioration cell in convenient increments. (Provide tor individual operations of each cylinder since vessel weight is generally not equal on all supports and pertormance differs slightly ‘among cylinders.) © Advantages The effects of vesse! deformation under live No extra structural members or devices are load — load redistribution, wall cistortion, requited to support the calibration unit suppor! bracket tlt, vessel elongation — will be observed and, if necessary, corrected. VESSEL SUPPORT eae STAY R00 / ayer LOAD PLATE BEARING PLATE Cauannon vom cet, Lo ewacire Sans grass wer] Cc [ADAPTER PLATE PERMANENT LOAD CELL EXPANSION ASSEMBLY (OPTIONAL) HYDRAULIC CYLINDER SPACER BLOCK OR PAD STRUCTURAL SUPPORT (CYLINDER MOUNTING PLATEpiping design General rules A free-standing vessel fully supported by load transducers on firm suports has a weigh system accuracy approaching that of the load transducers and the instrumentation alone, a value well below 0.1%. Experience has shown the one factor most often com- promising weigh system accuracy to be the mechanical restriction arising from piping connections with insutticient flexibility or displacement capability. To minimize these problems, BLH Electronics recommends that all piping attachments to the vessel be made as flexible as process materials and temperature will allow, specifically (On high pressure systems (> 25 psi), use schedule 10 (or 5) stainless steel pipe instead of schedule 40 carbon steel for a 150- 300% increase in flexibilily on the final run to the vessel, Filament-wound, glass-reintorced piping is suitable for applications up to 200°F and 425 psi when the process chemistry allows. Expansion joints and universal joints with adequate pressure ratings, both metallic and nonmetallic, are also recommended provided that they are positioned horizontally 10 avoid vertical thrust forces. ‘On low pressure systems { < 25 psi), use non- metallic flexible piping devices whenever possible. Major suppliers now carry Tetlon, elastomers, and plastics, all at least three times less stiff and often more wear resistent than the metallic counterparts. Be aware that metallic components covered with metal braid. are sources of frictional, hysteresis type forces due to the contact between the metal bellows and braid; in ane test, a horizontally installed 2" diameter metallic expansion joint was shown toalter vessel output by 50 Ibs (22.7 ka) ‘depending upon the initial offset of the joint before the calibration run Be careful when using forces and deflections calculated by computer for vessel and piping Experience has shown such values to be generally oblivious to the significant vessel- support and piping-support deflections encountered in the field. Refer to “Accuracy \Vessel Piping, and Support Deflection’ (p. 35) for often ignored deflection sources. ‘Support the piping from the same floor the vessel rests upon; do this at least for the support closest 10 the vessel. This tends to ‘minimize differential thermal expansion and differential support (loor-to-tloor) detection problems between piping and vessel. Reter to Special Design Considerations, ‘Piping Flex ibility’, for supportive discussions. For minimum piping restriction, consider coid- springing all piping at ftup so that the mating flanges on piping and vessel align treely before being bolted together. This would be particularly beneficial on lighter weigh vesse!s Al piping tends to sag fromits theoretical (design) position due to its own dead weight exterior insulation, and live contents. Its there- fore good to practice to inspect al piping runs between weigh vessel and first pipe support for adequate clearance around each line: @ minimum space of 1 inch (25.4 mm) should exist between any given pipe and another pipe, steelwork, ductwork, etc. All oo often, field installation crews fiting and insulating pipes violate the intended spacial geometries leaving only narrow gaps between lines which become sources for nonlinear mechanical restriction to the weigh vessel. Sealed systems FLEXIBLE PIPING DEVICES (Expansion joints, universal joints, flexible couplings; flexible hoses and ducts) Locate these devices in horizontal piping runs adjacent to the weigh vessel ta avoid vertical thrust forces from varying internal pressures associated with material flow ang process chemistry. Its preferrable to have these forces act laterally where they trans: late into minor horizontal forces and insigniti- cant overturning moments an the vessel, UNIVERSAL oN RECOMMENDED IPE ‘SUPPORT ARRANGEMENTSealed systems (continued) © FLEXIBLE PIPING DEVICES (Expansion joints, universal joints, flexible couplings; flexible hoses and ducts) (continued) Donat stretch or compress these units excessively or use them to compensate for initial piping misalignments at fitup, est their stitiness characteristics be altered. Above all if flexible devices are used vertically. donot rest the vessel upon them and then install the primary vessel supports with the vessel in that position...this field installation practice is not uncommon on smaller vessels. Obviously, a corrugated device will lose much of its flexibility wnen tightly compressed. Where large displacements must be ‘accommodated with low force, use hose for the final leg to the vessel. If this is not Practical, consider using two expansion joints or flexible couplings in a series as a “universal joint”, or a flexible hose bent U-shaped as a “travelling hose’. This is particularly important for low capacity systems where ‘even small piping forces will disturb weigh system stability EXPANSION JOINT FH ACE wit —) UNIVERSAL ONT THERMAL EXPANSION HOSE BEARING SEAMS eS S20 NG, LOAD TRANSOUCERS a ‘AND EXPANSION ASSEMBLIES Do not use rigid insulation on expansion joints and tlexible hoses or their lateral flexibility willbe compromised; use heat-trace cable instead. piping design In some systems, process pressure is high enough to force expansion joint flanges tight, against limit bolts (supplied for that purpose), If joint length is short compared to diameter, perhaps 1:1 oF less, joint flexibility may be ‘compromised by friction of bolts against flanges. Lateral flexibility may be restored however, if limit bolts are replaced with properly terminated steel cable of equivalent tensile strength, This fix” should not be necessary in a properly designed system; itis. mentioned here as a means of improving the flexibility of existing piping in a retrofit installa- tion utr Bours (supped) i PRESSURIZED EXPANSION ONT ‘STEEL CABLE (aerate) ‘Amore frequent problem occurs when short flexible devices absoro the torque acting about the pipe axis and “wind up” until the limit bolts jam tight. The resultant loss of flexibility may impair weigh system accuracy particularly it dead weight calibration had been pertormed with the system cold, before the pipe rotation ‘occurred. If possible, installa pipe quide ahead of the flexible joint to arrest the rotation. Failing that, a simpler “fix” may be to loosen the bolts, This will reduce the stiffness somewhat, ut not entirely, due to the continued torque imposed on the joint. Flexible devices of nonmetallic materials otter more flexibility in less space and with less vibration transmission than metal counterpart. ‘These benefits plus, variously, increased wear, corrosion and fatigue resistance makes non- metallics highly attractive when the process pressure and temperature requirements can be met