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DEAD WEIGHT TESTERS

PURPOSE
The purpose of this procedure is to ensure that all maintenance, repair or rework carried out
on Dead weight testers is to the highest possible standard and in line with statutory
regulations. These procedures should be used with Job Card 1002B.24 and its associated
flow chart WI/AP 2001. Should it be necessary only to inspect and recalibrate the instrument
a calibration/inspection certificate should be completed in place of the job card.
RESPONSIBILITIES
It is the responsibility of the workshop supervisors to ensure that these procedures are fully
implemented with assistance being given by workshop foremen and instrument technicians.
Immediate release procedures may be used in line with QAP/AP 1002 of the quality
assurance procedures.
1.0 EXTERNAL DAMAGE INSPECTION
1.1 Thoroughly examine unit for signs of transit or operation damage. Particular attention
should be paid to transport containers, pump, piston and pressure connections. Report any
damage to workshop supervisor.
2.0 CLEAN/FLUSH EXTERNAL/INTERNAL
2.1 Remove unit to a suitable wash down area and completely clean all external surfaces with
detergent or solvent. Carefully clean weights, pressure piston and pump with a suitable
degreaser spray. Empty reservoir and flush through all flow paths until clean. Strip out pump
assembly and thoroughly clean with suitable degreaser.
3.0 INSPECT INTERNAL Vol 4 Sect 13c
3.1 Inspect all sealing areas of pump liner and piston for damage and corrosion, check all
pipework and manifolding.
4.0 HOLD POINT, DAMAGE REPORT
If during the preceding sections any damage has been found whether due to shipping or
corrosion the workshop supervisor should be informed. It may be necessary to hold the
equipment in this condition for client, insurance or other third party inspection.
5.0 ADDRESS FAULTS ON OPERATIONS REPORT Vol 4 Sect 13c

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5.1 Specific faults should be repaired in accordance with the manufactures literature or
workshop supervisors instructions. Any faults will be highlighted in the remarks column
of the job card.
6.0 CHECK PUMP, PISTON AND WEIGHTS Vol 4 Sect 13c
6.1 Confirm all seals, O rings and components are suitable for service, reassemble dead weight
tester in accordance with the manufacturers instructions, fill reservoir with clean hydraulic
oil and pressure test to maximum working pressure.
DEAD WEIGHT TESTERS
7.0 CALIBRATE AGAINST MASTER DWT Vol 4 Sect 13c
7.1 Determine the period of calibration for the type of instrument. Offshore dead weight testers
are calibrated prior to each job. Permanent laboratory dead weight testers are calibrated
every year against the master dead weight tester in the lab, which is sent to a certified test
house annually for recertification against national standards. Calibration shall also carried
out whenever a problem has been reported regarding discrepancy in pressure.
7.2 Connect tester to be calibrated to master dead weight tester using a short hose with
minimum inside diameter of 1/4" purge through to eliminate air. Sequentially measure all
test weights against master DWT. recording any differential.
7.3 Records of calibration shall be retained and details recorded shall be in accordance with
Quality procedures QAP/AP 1101.
7.4 The limits of accuracy shall be equal to or better than those stated by the manufacturer.
8.0 CLEAN PAINT AND MARK, GREEN TAG
8.1 On completion of the maintenance programme the unit and shipping container must be
thoroughly cleaned and assessed for general condition of paintwork. Normally units
require a touch up or new top coat if however large areas of unprotected metal are evident
or if paint is blistering, peeling or flaking the unit will require refurbishment and a
protective coating compatible with the original specification.
8.2 The DWT identification number shall be stencilled in a contrasting colour on the unit, and
its transportation boxes for weights characters should be a minimum of 25mm high.
8.3 Identification of inspection status is shown by the green tag system, when maintenance is
complete the label is attached to the unit or its transportation box detailing job number,
instrument technician and test date. There should also be a "Calibration due" sticker

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attached to the unit in the case of workshop dead weight testers
9.0 PREPARE FOR SHIPPING - THREAD PROTECTION
9.1 Ensure carrying case handles and threaded bar nuts are secure, it is essential that weights
are not interchanged between DWT's