IND SER TankScalesFood OT 107 WP TankScale Checklist EN

IND SER TankScalesFood OT 107 WP TankScale Checklist EN
Tank Scale Service Checklist
Specifying Service
for Optimized Weighing Processes
Selecting the right weighing equipment is an important first step to ensuring that your
weighing processes are able to meet internal and regulatory requirements. Specifying
the right services for the equipment is the next step to making sure that your project is a
success and that you maximize your return on investment over the life of the equipment.
Like other modern, adaptable and high-performance
systems, weighing equipment must be installed, configured, tested, qualified, and maintained in a manner
that delivers optimum business performance. Additionally, weighing measurements must be sufficiently
accurate to ensure the quality of your process, contribute to your profitability and be documented in compliance with applicable regulations, standards and
specifications.
Utilize this checklist to ensure that you have considered
the necessary equipment specification, installation,
configuration, calibration, certification, and maintenance services to assure that your equipment always
performs within your expected process tolerances.
Contents
1 Equipment and Service Requirements
2 Equipment and Service Specification
3 Installation and Start-up
4 Equipment Qualification for Validated Processes
5 Calibration and Certification
6 Maintenance, Training and Support
7 Factory Service
Service Checklist
1 Equipment and Service Requirements
The services that you require must be selected to meet
the objectives of your project, in accordance with the
requirements of your process, and to complement the
capabilities of your personnel. This document can
help you in this assessment by providing guidance for
B
I
A
specifying recommended services. Requirements for
equipment and services are divided into five categories with checklists of service tasks and recommended
steps, to meet your objectives. Each task step is classified according to level of difficulty as follows:
Basic – Performed by individuals with knowledge of weighing equipment and concepts
Intermediate – Performed by individuals with specialized know-how of weighing equipment and processes
Advanced – Performed by individuals with training and tools from the equipment manufacturer
2 Equipment and Service Specification
To ensure consistent product quality and prevent out-ofspecification results or bad production batches, it’s essential to select the proper equipment and required services.
Equipment
and Service
Specification
Preparatory
Tasks
Compliance with all regulations applicable to your weighing process must be investigated and should be documented for future reference. The below checklist will help
you determine the proper equipment and service selection.
Classification
Recommended Steps
B
1. Specify the application of the equipment
x
2. Determine the environmental factors for the equipment
x
I
3. Determine the minimum weight to be measured and
required accuracy
4. Determine the largest gross load expected to be weighed
x
x
1. Verify the equipment matches the application of your
weighing process
x
2. Review the environmental conditions and ensure the proper
selection
x
3. Specify the level of protection for hazardous environments
x
4. Specify the level of protection for wet environments
x
5. Determine the weighing accuracy required
x
6.Define the required weighing accuracy safety factor
x
7.Specify the standards and regulations this equipment is
required to meet
Service
Selection
1.Determine your personnel’s weighing equipment competencies and training needs
x
x
2.Determine the appropriate weight sets and SOP (Standard
Operating Procedure) for periodic testing
3.Define the Installation and Setup processes
2
METTLER TOLEDO - White
x
x
4.Determine the Equipment Qualification documentation
requirements
x
5.Define the appropriate maintenance and calibration
schedule
x
6.Train the equipment operators on proper maintenance
x
Paper - Tank Scale Service Checklist
My Notes
x
5. Determine the appropriate weights & measures authority
and appropriate industry regulations
Equipment
Selection
A
© 2013 Mettler-Toledo, LLC
Service Checklist
3 Installation and Start-up
Proper installation of weigh modules for a tank scale
is complex because the total weighing system performance is dependent on many factors. Often this is
made more complex by the setting of advanced operational parameters and configuring and testing for
network integration of instrumentation. A successful
installation begins with an assessment of the environment of use and an evaluation of how equipment
capabilities can be matched to process requirements
and operational processes. Next, the equipment must
be properly installed, wired, adjusted, configured,
integrated and tested.
The final steps are confirmation of the operation and
accuracy of the equipment in the process where it
is utilized and familiarization of your personnel with
operational and maintenance procedures.
Weigh
Module
Installation
Recommended Steps
Preparatory
Tasks
1. Confirm the suitability of the environment where the equipment
will be utilized
x
2. Confirm the weighing vessel is properly constructed to
accept the weigh modules
x
3. Confirm the foundation support is adequate
x
4. Confirm the suitability of any live to dead connections
(pipes, cables, etc.)
x
Weigh
Module
Installation
Classification
1. Attach weigh modules to weighing vessel
B
x
4. Run and terminate weigh module cables to junction box
x
5. Route and terminate instrument cable from terminal to
junction box
x
Classification
Terminal
Installation
Recommended Steps
Preparatory
Tasks
1. Confirm application, power source and environmental
suitability of the equipment
B
I
A
2. Confirm regulatory, weighing performance, process work
steps, data handling, peripheral and network interface
requirements
x
3. Evaluate the installation environment to check that desired
weighing performance can be achieved
x
4. Verify the condition and contents of the terminal package
x
Mounting
1. Determine the optimal mounting location for operator efficiency and/or system integration and mount the terminal
x
Install Other
Hardware
1. Install additional interfaces and/or optional components as
appropriate
x
2.Set any switches and jumpers as required for sensor and
interface compatibility
x
x
x
5.Route power wiring and make power connection to terminal
x
6. After confirming a safe operating condition, power-up the
terminal
x
Paper - Tank Scale Service Checklist
My Notes
x
4. Install RF filtering components as specified
METTLER TOLEDO - White
My Notes
x
3. Route load cell, peripheral, device cables/wiring into the
terminal enclosure and make connections
3
A
x
2. Position weighing vessel on the support foundation
3. Attach weigh modules to support foundation
I
© 2013 Mettler-Toledo, LLC
Service Checklist
Operational
Tests
Scale
System
Operational
Test
Terminal
Programming
Setup
Standard
Configurations
Setup
Terminal
Application
Data
Classification
Recommended Steps
B
1. Apply power to scale terminal
x
I
3. Check the distribution of load between weigh module supports
x
4. Adjust weigh modules to achieve proper load distribution
x
5. Confirm scale operates properly over each weigh module
x
Classification
Recommended Steps
B
I
x
2.Determine and set the scale filter parameters to ensure stability and required responsiveness
x
3.Enable/setup peripheral communication and network interfaces as appropriate
x
1.Enable transaction log for legal-for-trade applications or
per regulatory requirements
x
2.Select the tolerance type required
x
3.Enter article data into the article database
x
1.Assign and confirm connections to the needed serial COM
and network ports
x
x
2.Configure discrete I/O attributes
x
x
x
5.Configure analog output settings
6.Configure PLC settings to match PLC requirements
x
7.Setup print and report templates
x
x
8.Test communications for proper operation
x
1.Configure, save, store, and upload templates
2.Conduct a print test for each print out format to ensure
proper layout and operation
x
x
3.Configure tare, target, and message table reports
4.Print tare, target and message table reports to ensure
proper data entry
4
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x
1.Design soft-key setup to optimize operator efficiency
x
2.Enable the ID soft-key for the ID Function
x
3.Enter terminal asset information, including scale base,
company, or other desired identification
x
4.Update time/date format and information
x
5.Enable graphing displays and language preferences
x
6.Configure any remaining soft-keys
x
7.Configure maintenance settings
x
Paper - Tank Scale Service Checklist
My Notes
x
4.Setup email alert parameters for service events
Advanced
Terminal
Configuration
A
1.Set terminal scale parameters for scale type(s), capacity,
readability, motion, alternative units, zero and tare functions
3.Setup File transfer Protocol (FTP) usernames, access rights
and passwords
Setup
Terminal
Communication Data
My Notes
x
2. Confirm weigh module communication to the terminal
4.Backup the target table and message tables with back up
tool
Setup
Terminal
Integration
A
© 2013 Mettler-Toledo, LLC
Service Checklist
4 Equipment Qualification for Validated Processes
There is an increasing need for assurance that prodprotocols to guide and document the installation and
ucts are safe and of a consistent quality. Consequently, operational performance testing of the equipment.
as a manufacturer, you must document that processes This ensures that you are able to achieve and maintain
are proven and that equipment is qualified to produce
the qualified state, that weighing processes are caparesults that meet specifications. Equipment Qualible of delivering results that meet quality requirements,
fication uses Installation Qualification, Operational
and that the risk of an audit challenge is reduced.
Qualification and Performance Qualification (IQ/OQ/PQ)
Equipment
Qualification
Installation
Qualification
(IQ)
Operation
Qualification
(OQ)
Performance
Qualification
(PQ)
5
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Classification
Recommended Steps
B
I
A
1.Unpack, verify and document the condition and contents of
the packages
x
2.Record the location of the equipment documentation
x
3.Document the suitability of equipment location and
environment
x
4.Describe and diagram the equipment configuration
x
5.Document the scale terminal and scale configuration and
installed accessories and peripherals
x
1.Document the configuration of the terminal, scale(s) and
peripherals and confirm their suitability
x
2.Record the details of the scale calibration; see the
Calibration and Certification Checklist for details
x
3.Document training of scale operators and other personnel
on proper use/maintenance of the scale system
x
1.Create Standard Operating Procedures (SOP) for periodic
performance testing and documentation
x
2.Record the details of applicable SOPs
x
Paper - Tank Scale Service Checklist
My Notes
© 2013 Mettler-Toledo, LLC
Service Checklist
5 Calibration and Certification
Scales can help increase business performance,
ensure product quality and increase revenue by lowering costs. It is easy to erroneously assume that
the weight value displayed is the exact weight of the
object or material on the scale. However, this is not
true; every measurement has an uncertainty associated with the measurement device’s capabilities, the
environmental conditions of the measurement and
the weighing process. The only way to determine the
suitability of a measurement for meeting your process specifications, or for delivering acceptable cost
and revenue impact, is to calibrate the measurement
device with a traceable reference standard and to
determine accuracy. Additionally, to have traceability
for your process, you must document calibration
results and certify that measurements meet quality
and regulatory requirements. Finally, for critical processes or when a measurement device is used at the
low end of its range, it is critical to determine measurement uncertainty and minimum weight.
Calibration &
Certification Recommended Steps
Preparatory
Tasks
Classification
B
I
1.Evaluate / confirm calibration and certification requirements
according to process, quality, regulatory, and/or industry
requirements (Pass/Fail Determination, Minimum Weight
Determination, Customer Specifications, etc.)
2.Decide if “As Found” results should be determined and
documented
x
x
x
5.Select sufficient reference weights of the required class and
tolerance according to the scale classification
Testing
Procedures
“As Found’
x
6.Select or record device serial number, model and
metrological details
x
7.Select or record scale owner, location, asset and other
information
x
1.Perform and record results of tests that were determined to
be required
x
2.Perform and record results:
• Sensitivity Test
• Eccentricity Test
• Linearity Test
• Repeatability Test
x
Make
Adjustments
1.Make any needed adjustments to the scale and terminal in
order to improve weighing performance to meet requirements
Testing
Procedures
“As Left’
1.Perform and record results of tests that were determined to
be required
x
2.Perform and record results:
• Sensitivity Test
• Eccentricity Test
• Linearity Test
• Repeatability Test
x
1.Record comments regarding the condition of the calibration
tests or other relevant information
x
2.Record the next calibration due date
x
Create
Certificate
x
3.Calculate measurement uncertainty and minimum weight
values (as required)
4.Print and archive the test certificate
x
x
5.Review test results to ensure that scale is suitable for use
in the required processes and applications
6.Check if re-verification is required
6
METTLER TOLEDO - White
Paper - Tank Scale Service Checklist
My Notes
x
3.Select an appropriate calibration procedure and certificate type
4.Perform a visual inspection of the weighing system’s
operational condition
A
x
x
© 2013 Mettler-Toledo, LLC
Service Checklist
6 Maintenance, Training and Support
Proper maintenance according to factory specifications
will significantly improve weighing equipment uptime
and performance and extend its life. Preventative
maintenance should be periodically performed with a
frequency appropriate to the type of equipment, application environment, regularity of use, and criticality of
the equipment to your process, product quality and
Weigh Vessel
Maintenance
Physical
Condition
Checks
downtime costs. Additionally, planned maintenance
can make your costs more predictable. You should also
have a training plan to ensure an effective start-up of
any new weighing process and to provide for the onboarding of new employees. Finally, make sure that you
have a support plan and processes that provide access
to the expertise that you need when you need it.
Classification
Recommended Steps
B
1.Remove power from scale terminal
x
2.Check for buildup of foreign material and clean as required
x
I
3.Inspect the scale for signs of excessive wear or exposure to
water or corrosive materials
x
4.Confirm that the floor or structure where the scale is installed
is in suitable condition
x
5.Inspect inlet and outlet pipes for scale interference
x
6.Inspect weighing vessel and any connections to the scale for
damage
x
8.Inspect bumper gaps (if applicable) and anti-lift devices for
clearance and secure fastening
9.Inspect stabilizers (if applicable) for proper adjustment and
secure fastening
x
x
x
10. Confirm scale is level, unobstructed, clean and ready for use
1.Restore power to the scale terminal
2.Confirm the scale is zeroed and returns to zero after loading
3.Perform a calibration test and seal as required (refer to
Calibration and Certification)
7
METTLER TOLEDO - White
Paper - Tank Scale Service Checklist
My Notes
x
7.Confirm the junction box lid and cables are properly sealed
Operational
Tests
A
x
x
x
© 2013 Mettler-Toledo, LLC
Service Checklist
Classification
Terminal
Maintenance
Recommended Steps
Preparatory
Tasks
1.Identify and document issues that have occurred since the
last maintenance
I
x
3.Connect to terminal and backup configuration, maintenance logs and data
x
x
1.Look for signs of excessive wear or exposure to water or
corrosive materials
x
2.Look for damage to the keyboard or display
x
3.Make sure the terminal cover and cables are properly sealed
x
x
ing and damage
x
5.Verify terminal and scale system grounding
1.Restore power to the scale terminal
x
2.Confirm terminal safe operational mode for tests
x
3.Zero scale and perform a calibration test (refer to Calibration and Certification)
x
4.Access terminal diagnostics to record load counts and
calibration values (as required)
x
5.Access terminal statistics to record number of weighments,
overloads, etc. (as required)
x
x
6.Perform keyboard and display tests
7.Check communication to peripherals and networks
Final Review
8
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x
8.Test and confirm I/O function (as required)
x
9.Check for error alerts during normal operation
x
10. Add entry to maintenance log and back up terminal
x
1.Seal terminal as required by customer or Weights and
Measures regulations
x
Paper - Tank Scale Service Checklist
My Notes
x
4. Inspect terminal cables for loose connections, proper rout-
Operational
Tests
A
2.Examine terminal maintenance logs for signs of prior
operational issues or potential failure
4.Remove and lockout terminal power
Physical
Condition
Checks
B
© 2013 Mettler-Toledo, LLC
Service Checklist
7 Your Qualified Service Provider
Contact METTLER TOLEDO to ensure you maximize the return on your investment. Our technicians have the
advanced skill-set to safeguard the life of your weighing equipment through these comprehensive service
offerings:
Equipment & Service Specification
With GWP®, METTLER TOLEDO performs a comprehensive analysis of
your weighing process and recommends the exact weighing equipment along with the right services.
Installation and Start-up
Includes proper installation in the
working environment, setup and
configuration for optimal operator
efficiency, and interface to peripherals, data collection or automation
systems.
Equipment Qualification
IPac delivers a professional installation for weighing equipment in
production and is designed to meet
the requirements of a validated
process.
Preventative Maintenance
METTLER TOLEDO provides the
right level of periodic preventive
maintenance to match equipment
utilization, process criticality and
equipment lifecycle.
METTLER TOLEDO will assist you in determining the key requirements before defining
a services program:
• How important is maximizing uptime to your process and business?
• What measurement accuracy will ensure required quality and profitability?
• What are your regulatory, quality and customer compliance requirements?
• How should your equipment be integrated into your process and systems?
• What is the optimal equipment configuration for your process and operation?
• Can your staff safely and productively operate and maintain your equipment?
GWP® Verification
A unique, science-based
service to certify the accuracy
of weighing processes
www.mt.com/gwp
Benefits of Using METTLER TOLEDO Service:
• Consultation for an optimal service plan to achieve your desired business results
• A global network of factory-trained technicians delivering exceptional service
• A field service force backed by local and global support personnel to provide ideal solutions
• Proprietary service tools to realize and maintain the best performance for your equipment
• Factory maintenance procedures to maximize your return on investment
• Consistent procedures to ensure measurement results that lower costs and increase revenues
• Certification solutions that are compliant with local and global regulations and standards
• Calibration services that are ISO17025 accredited, giving third-party credibility to results
Mettler-Toledo AG
Industrial
CH 8606 Greifensee
Switzerland
Phone +41-44-944 22 11
Fax +41-44-944 30 60
Subject to technical changes
© 03/2013 Mettler-Toledo AG
www.mt.com/service
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