Apache Stainless Blog

How to Troubleshoot an R-Stamp Repair

Thu, 12 Oct 2023 21:00:59 GMT

There are several reasons why an ASME-certified vessel may need service. However, the need for ASME R-Stamp Repair is very specific.

Any repairs to the pressures zones on tanks require an R-Stamp. A code repair is when a vessel’s “pressure boundary” needs repair. This could either be a cooling/heating jacket or the tank itself. A ‘non-code’ repair is when the non-pressure area of a tank needs repair.

Troubleshooting Accidents

In the case of an accident, such as a tool falling into the tank and causing damage; surface scratches and dents can typically be repaired on-site, provided they do not go beyond minimum requirements, with mechanical polishing or hand/wand electropolishing. While a scratch may be a non-code repair, any damage to the cooling/heating jacket will require an R-Stamp repair.

Troubleshooting Wear or Failure

Reduced agitator performance or failure is often due to worn parts, improper assembly, or a bent shaft. Agitator repairs may be addressed with the agitator manufacturer or the vessel manufacturer, depending on the situation, down-time, and severity of the failure. If the shaft breaks and causes damage to the “pressure boundary”, the R-Stamp repair will be necessary.

R-Stamp Repairs for Vessel Modifications

Vessel modifications often require an R-Stamp code repair. A new nozzle addition, or any weld to a code ASME vessel may require an R-Stamp repair. Component replacement and shell repairs are typically completed on site by a certified ASME repair service tech. Apache updates R-Stamp forms and are filed with the NB and the customer. A history of all repairs is indicated on the ASME data report.

Getting R-Stamp Repair Support

As mentioned above, It is important to note that any weld repairs to the ASME pressures zones on tanks, require an R-Stamp. Depending on the size of the vessel and type of repair, Apache’s service techs may be able to make repairs on site or in some cases, tanks are shipped back to the factory. Apache can provide factory or field location services including:

• Field service and troubleshooting to all types of stainless and high alloy tanks

• ASME / National Board R-Stamp repair and modifications

• Surface finish repairs

• Non-code repairs and modifications including piping and heat transfer jackets

• Seal and agitation repairs and modifications

• Accessory repairs

• Head and tank shell repairs

• Leak detection

• Audit and service contract available

Visit Apache Field Services if you have an R-Stamp inquiry.

Guide: Heat Transfer Surfaces EXPLAINED

Thu, 21 Sep 2023 13:46:31 GMT

Thermal heat exchange surfaces control the temperature in the vessel and the quality of the contents. Jacketed vessels are used in many industries and can be used to remove the elevated heat of reaction (heat reactor vessel) or reduce the viscosity of high viscous fluids. In an updated eBook, the Apache team has fine-tuned a guide (link) to explain applications, pressure criteria, and ASME requirements for Conventional Jackets, Dimple Jackets and Half Pipe Coil Jackets.

Conventional Jackets
Conventional jackets are an open jacket with an annular space containing the heat transfer media on the exterior surface of the tank. In some instances, internally welded baffles within the conventional jacket control the flow of the heating or cooling agent. In Apache’s experience, water, oil, or heat transfer fluid is typically used as heat transfer agents for conventional jackets.

Variable coverage areas and pressures are available in conventional jacket designs.

Dimple Jackets
Dimple jackets utilize a thin gauge stainless steel layer that is plug welded to the vessel shell in a regular pattern. The punched and spot-welded areas are called dimples, which create turbulence of the heating or cooling fluid flowing through the jacket. The dimple jacket design allows for thinner vessel shell walls than a conventional jacket design due to the strength of the dimple pattern design.

Dimple jackets are manufactured in several different pressures and patterns. Apache fabricates with 12 ga. and 14 ga. material. Each pattern is validated, and proof tested per ASME regulations. Apache has proofed and certified designs up to 1 ¾” at 200psig at 300o F but can go to higher temperatures depending on the application.

Half Pipe Coil Jackets
The half-pipe jacketed vessel has a split pipe (split evenly or rolled formed sheet) wound around the vessel and welded into place. This design provides optimal strength and can be rated up to 500psig. Half-pipe jackets are recommended for high-temperature and liquid heat-transfer applications.

Material used for half-pipe jackets are commonly 304, 304L or 316 and can be welded to a range of alloys. Sound welding practices allow the half pipe to be welded to high alloys.

Compliance engineering for industries requiring ASME code certification and fabrication is what we do. Dedicated project engineers provide control over calculations, component selection, compliant designs, approvals, testing and certification. Apache has experience and reputation with inspectors, agencies, and governing officials for successful and efficient compliance vessel projects.

Download the eBook “Heat Transfer Surfaces for ASME Vessels” (link) for ASME and application information about heat transfer methods.

Trends in Custom Vessel Manufacturing

Mon, 15 May 2023 13:26:15 GMT

In the last few years, Apache’s essential manufacturing customers have faced familiar developments in supply chain and resources. In a round table query of Apache’s sales and engineering team, here are the top 3 post-pandemic equipment trends and resource challenges experienced by our customers.

1. Solutions to Support Manufacturing Flexibility

The need for flexible equipment and processing tasks is common among pharmaceutical and biopharma processors working with Apache. Whether it is customized batch processing or equipment that needs to accomplish more than one task, Apache has met many processing goals with custom sanitary design vessel solutions.

Apache’s experience in compliance-engineered specialty tanks, including custom mix tanks, jacketed vessels, extraction equipment, columns, and evaporators, manufactured to custom specifications with the expertise of ASME (and other global standards) engineering and control.

Processors are also leveraging automation to create efficiencies in flexible production. Automated CIP (clean-in-place) vessels, heat exchange programming, and recipe controls help with automation goals for many manufacturers requiring custom vessel solutions.

2. Nearshoring Partnerships

The pandemic, the Suez Canal disruption, and economic tensions with China have lasting sourcing effects on many industries, which continue to drive businesses to innovate their supply chain strategy. New customers are prioritizing availability, quality, service, and customization over cost to grow new partnerships with Apache.

Entire industries are moving toward nearshoring sources. In one example, the semiconductor industry is taking advantage of the CHIPS and Science Act (2022) to help the US regain the lead in semiconductor Chip manufacturing. Apache has been a long-time manufacturer of custom vessels for specialty chemicals used in the chip manufacturing process and is positioned to provide custom vessels to additional partners.

3. Supporting Customers with Expertise / Services

Affecting every industry are workforce shortages and lack of experience in technical and skilled positions. As an employee-owned company, Apache can retain experienced employees who work alongside recent graduates rounding out effective teams. Apache is designing our support strategy to help customers with compliance education and provide a consultative approach on projects to troubleshoot issues before they drive cost or timing.

Professionals new to industries requiring custom stainless vessels are welcome to read “Design to ASME Submission”, or “Guide to Factory Tests and Certifications for ASME Tanks and Vessels”. Our eBooks and blogs are written to help customers learn about the importance of compliance engineering and manufacturing.

With a legacy of compliance engineering and manufacturing comes a dedicated quality control program. Apache has excellent relationships with inspectors, government agencies, and compliance officers to keep your project moving forward. We have a strong quality assurance team with plant-wide initiatives for continuous improvements. Our entire company from our compliance and quality engineers to our ASME welders, knows how to facilitate ASME, PED and other global compliance regulations.

Requirements for the Repair or Alteration of ASME Stainless Pressure Vessels

Tue, 11 Apr 2023 14:51:48 GMT

Whether an accident, environmental damage, or refurbish needs, vessel repair may be necessary at the customer site. It is important that whoever works on ASME pressure vessels is qualified, certified, and experienced. The National Board, the regulatory commission for ASME, requires an ASME R-Stamp for the repair or alteration of pressure vessels.

Repair areas and welds should be carefully assessed before repair. Qualified technicians may use die penetrant, x-ray, or ultrasonic devices to inspect welds and surface defects.

If the vessel requires repurposing or refurbishment, qualified ASME engineering professionals must be involved to make sure the changes are compliant with ASME.

All nozzles and attachments added to the pressure vessel must be ASME compliant. In addition, there are specific requirements for materials by ASME, including all attachments that are welded to the pressure boundary.

The welding procedure for ASME vessel repair is extensive to include rules for joints, torch cutting, arc gouging, grinding, reinforcement and post weld treatments.

For all repairs or alterations to stainless vessels, it is essential to know the materials and heat treatment requirements. The owner of the vessel, the manufacturer of the vessel, or the National Board (if registered) will have a data report on the vessel which includes a history of all repairs and ASME data for the vessel.

Sufficient time for the proper repair or refurbishment of the vessel is also a requirement. The tank or vessel needs to be off-line for proper testing, prep, verification, and compliance documentation to be accomplished. Repair or refurbishment may take a few days to complete, so discuss the plan and process with your repair organization. Apache provides a realistic timeline estimate after the results of the repair / refurbish assessment.

Apache Stainless, as a qualified ASME R-Stamp manufacturing organization, will work with the customer, NDE (Non-Destructive Examination) firm (if required) and third-party inspector during the process and will provide the R stamp documentation to the customer and the National Board (NB) when completed.

There are significant requirements for R-stamp approval including:

Qualified material documentation
Supporting calculations
Qualified and certified welder, and welding procedures
ASME inspector and witness to R test and attachment of stamp
Registering with the National Board.

Apache’s technicians are fully certified ASME welders. With over 40 years’ experience in vessel manufacturing and continued excellent inspection ratings from ASME auditors, Apache is a solid partner for ASME compliance design, manufacturing, and repair.

Top 3 Indications you Need an R-Stamp Repair

Fri, 15 Jul 2022 20:40:41 GMT

ASME (American Society of Mechanical Engineers) and NB (National Board) certification is an extensive procedure. An R-Stamp repair is required by the NB when the pressure vessel’s barrier is broken. These repairs include, but are not limited to, weld repairs, installation or replacement of nozzles, and attachment of components related to pressure parts. Here are 3 situations that may ultimately require recertification of ASME:

Pressure boundary failure
Field Modification
Accident

Pressure Boundary failure

Leaks coming out of the jacket, inlets, or pipes may be a sign that you need repair to the pressure- affected components or zone.

Examine the insulation cladding weep hole, normally in the lowest area of the cladding, to check for flow of fluid or steam that could be coming from the heating and cooling jacket. This may be the result of a crack or defect in the jacket.

Symptom of increased water, steam, or glycol usage in the process, can occur in all types of ASME U or ASME UM vessels and all styles of jackets (shell, dimple, or half-pipe) as a result of the cracking or defect.

Field Modification

A new nozzle addition, or any weld to a code ASME vessel, for even a ladder bracket, may require a certified R-Stamp repair.

Before any field repair or modification of an ASME pressure vessel, consult the manufacturer or a qualified ASME / NB repair service. As the owner of an ASME pressure vessel, you are responsible for workplace safety and the liability and ASME certification of all repairs.

In extreme cases, unqualified work may result in scrapping the vessel. Material traceability and other ASME processes required for NB filing and certification become difficult to verify and prove.

Accident

In some accidents, improper thermal cycling may cause cracking of inlet and outlet areas of piping and cause stress detachment in the welds of the jacket and base material.

A damaged vessel wall or vessel internals from a tool dropping can cause damage to require repairs to a pressure boundary zone.

It is important to update organizational compliance standards, training, and work procedures to assess how damage and safety issues occur to develop prevention measures.

Whether a pressure boundary failure, field modification, or accident causing the need for repair, the first step is a Repair Evaluation. When accessible, thermal imaging, dye penetrant examination, or a radiographic inspection can help locate the defective areas. Then an estimate time of job is performed with a schedule for production downtime. Apache’s qualified ASME R-Stamp repair technicians work with an inspection firm for R-Stamp repair. Apache Stainless, as a qualified R-Stamp manufacturing organization, will work with the customer, NDE firm (if required) and third party inspector during the process and will provide the R stamp documentation once complete.

Component replacement and shell repairs are typically completed on site by a certified ASME repair service tech. Apache updates R-forms and are filed with the NB and the customer. A history of all repairs is indicated on the ASME data report.

There are significant requirements for R-stamp approval including:

Qualified material documentation
Supporting calculations
Qualified and certified welder, and welding procedures
ASME inspector and witness to R test and attachment of stamp
Registering with the National Board.

Apache's Technicians are fully certified ASME welders. For over 40 years, Apache continues to maintain rounds of audits and inspections from ASME compliance and safety professionals that speak to the consistency of the welders and the effectiveness of the quality control department. We hold these certifications: ASME U Certificate, ASME UM Certificate, National Board of Boiler & Pressure Inspectors R Certificate, and National Board of Boiler & Pressure Vessel Authorization to Register Certificate.

10 Reasons Why Ethanol Producers Choose Apache Stainless as Their Tank Manufacturer

Tue, 19 Apr 2022 15:28:50 GMT

1. The number one reason for partnering with Apache for your ethanol vessel is our expertise of over 40 years supplying tanks for ethanol and biofuel production. We specialize in heat exchange surfaces, pressure vessels, custom mix tanks, evaporators, and extraction equipment made from stainless and other high alloys.

2. Apache has the capacity for specialty large tank projects. We have custom-designed and fabricated tanks from one gallon to 160,000-gallons.

3. Apache has a good standing in the community and the technical college to recruit and retain skilled fabricators. Our welders are ASME certified and are graduates of rigorous step programs and maintain a continuous excellent safety rating.

4. We have control over advanced manufacturing processes. Our tenured engineering staff is experienced in project management of ASME specialty pressure vessels.

5. Apache is employee-owned, a culture that drives efficiencies, collaboration, and innovation. Our employees fully understand that customer satisfaction is directly related to the success of our company. Located in Beaver Dam, in rural Dodge County Wisconsin, we have a strong midwestern work ethic.

6. In-House material finishes include robotic and mechanical polishing, pickle passivation (ASTM A380 & A967) Electropolishing (ASTM B912). There is no outsourcing of finishes, Apache handles any size to be polished, passivated, or electropolished.

7. Apache has a quality assurance team to coordinate testing and processes, TOP packages, and certifications, including ASME U, UM, CE Marking Permission, National Board of Boiler and Pressure Vessel Inspectors, UN DOT, and CRN (all provinces and territories.)

8. Backed by full ASME and other global standards, Apache offers numerous testing and certification required for compliance, including pneumatic testing, hydrostatic testing, liquid penetrant, saline testing, CIP coverage, base metal thickness, ferroxyl testing, positive material ID, ferrite levels, radiography, and UT weld testing.

9. Apache has dedicated transportation personnel and a fleet for specialized high and heavy load services. Our transportation team provides permits, escorts, and communications for large tank loads.

10 Our field service technicians have years of experience as tank fabrication and repair specialists at Apache. We fully support all stainless and high alloy vessel construction and refurbishment. We are ASME and National Board R-stamp certified for repairs and modifications. Our field service offering can be extended to audit and service contracts for preventative maintenance service preferences.

Sometimes Tank Damage Isn't as Bad as You Think

Wed, 06 Apr 2022 18:16:00 GMT

There are two main causes why a vessel may need service. There is a performance related issue, or there has been an accident.

The damage might be a bent agitator, or it might be damage to a side wall or baffles. We see these kinds of things all the time and we can fix them most of the time.
Depending on the size of the vessel and type of repair, Apache’s service techs may be able to make repairs on site or in some cases, tanks are shipped back to the factory. Apache can provide services including:

Repair and replace agitator shafts
Add agitation to a non-agitation vessel
Refurbish outlet valves, seals, or-rings, and gaskets
Relocate nozzles and fittings
Replace manways
Repair jackets (conventional, dimple, half-pipe)
Add cooling or heating coils
Detect and repair leaks
Refinish product contact surfaces
Repair sidewalls
Change bottom head configurations
Modify tanks, platforms, catwalks for repurposing
Convert non-pressured vessel to pressurized (if approved by engineering)

It is important to note that any weld repairs to the ASME pressures zones on tanks, require an R-Stamp. The R-Stamp is a certification required by the National Board of Boiler and Pressure Vessels for repair of an ASME tank or vessel.

Whether you have a critical repair or planned service, you need trained technicians who know how to maintain and refurbish pressure vessels. Our technicians are ASME certified with confined space training and have the tools and expertise to make repairs and provide consulting on underlying causes of problems to make recommendations for improvements.

Contact Josh Schladweiler, Field Services / Parts Manager to schedule service.

920-356-9900 Ask for Field Services/Parts

Josh.Schladweiler@apachestainless.com

Download the Tank Group Field Services flyer

Custom Vessel Design to Compliance - Steps to Success

Fri, 14 Jan 2022 16:24:06 GMT

DESIGN TO COMPLIANCE

Designing custom vessels to compliance, such as ASME or CRN, is a highly engineered approach. Certainly, manufacturers of the custom vessel must have required accreditation, but the engineering expertise goes beyond certification. The pressure vessel manufacturer must have experience and a reputation with inspectors, agencies, and governing officials to manage the compliance process smoothly and efficiently.

The process is complex, and we must educate customers about the important steps, all of which affect the project's outcome. The process includes consultation, project engineering, manufacturing, and compliance.

Consultation

When discussing the intent of the vessel with the Customer or Engineering Firm, the sales team works to learn more about the industry and process that the vessel will serve. This will often help us make recommendations on design attributes that the customer may not know this early in the design and vessel selection process. This is especially important in the absence of a formal specification package.

A scope alignment meeting occurs to discuss the proposal and services. This meeting may include revisions, due dates, milestones, review of pricing, terms, and conditions, and certification timelines and deliverables.

Project Engineering

After Apache receives the PO (purchase order), we assign the project to the engineer, and the kick-off meetings begin. Sales works closely with the project engineer to relay information back to the customer.

Engineering will perform final calculations, complete the design, consult with component manufacturers, and review designs with the customer. Construction, pressure, fixtures, and components must comply with ASME or CRN code.

Once the customer approves the design, Apache submits the compliant design to ASME, CRN or other faction approval and begins managing that process.

Manufacturing

The project engineer creates detailed drawings for the manufacturing process. Staff, fabricators, and welders are ASME certified. All welders are approved for the weld procedures required to make custom vessels.

Compliance

Project engineers work closely with manufacturing and quality assurance technicians to conduct the testing required for compliance. ASME testing and certification requirements include pneumatic, hydrostatic, liquid penetrant, saline, riboflavin, CIP coverage, material, base metal thickness, material trace, welder trace, Ferroxyl, PMI (Positive Material Identification) radiography, and UT. Apache provides in-house inspection services, which benefit customers with ASME projects. The documents are provided in the TOP (turnover packet) by Apache's Quality Assurance team.

Apache has been ASME certified for over 40 years. In addition to ASME, Apache is accredited in many other global standards, including CRN.

In addition to the "12 Steps to Compliance" video highlighted in this blog, learn more by downloading our e-book, "Road Map: Design to ASME Submission."

New E-Book: Design to Submission Road Map

Wed, 24 Nov 2021 15:32:00 GMT

Many of Apache's customers, come to us with a full specification outline to custom manufacture their tank or vessel. For pharmaceutical, life sciences and health industries, Apache often works with integrators who add their process technology to sanitary equipment supplied by Apache. We also provide vessel solutions to end-users who have process technology support or experience, and need a vessel manufacturer to help them meet their quality and compliance standards.

Specifications such as Fixtures and fittings are also part of the compliance engineered solution. When learning about the vessel's intent, we want to define what the process connection (or nozzles) are required, as well as the service for each nozzle. This will help to pre-plan the general layout and placement of the nozzles. For custom ASME or other standards, the nozzles that we use must be compliant-driven and support the pressure/temperature rating of the vessel.

In this e-book "Road Map: Design to ASME Submission", we offer project planning recommendations for vessels that require ASME or other compliance. It is especially helpful for engineers or purchasers new to the role of procurement of sanitary custom vessels and tanks. This detailed "road map" provides planning insight and knowledge to acquire custom-designed and manufactured ASME vessels with an understanding of compliance engineering.

It is very important to partner with a vessel manufacturer with expertise in the type of vessel and industry for the use of the vessel. In ASME applications, it is vital that critical staff, fabricators and welders be ASME certified. Experience as well as reputation are significant when working with inspectors, agencies and governing officials to keep the compliance process moving forward.

ASME is a leading developer of codes and standards in the mechanical engineering community. Apache has been ASME certified for over 40 years.

Read the e-book, and learn more about compliance, engineering and project management to meet goals and procure quality vessels that not only meet compliance standards, but project goals too.

Versatility of Dimple Heat Transfer Jackets

Thu, 07 Oct 2021 19:37:00 GMT

Versatility of Dimple Jacket Heat Transfer Thermal Processing

Apache’s engineers and fabrication experts are entrusted by many national and international processors to provide complex vessels with a host of compliant driven specifications and required quality protocols. With nearly 45 years of experience providing custom vessels, Apache has significant experience in thermal heat exchange surfaces.

Heat exchange surfaces can be designed for heating or cooling. Jacketed vessels are used in many industries and can be used to remove the elevated heat of reaction (heat reactor vessel) or reduce the viscosity of high viscous fluids.

Depending on the application, dimple jackets offer versatility in heating or cooling for almost any shape or size of vessel.

Dimple jackets are constructed with a thin gauge stainless steel layer that is plug welded to the vessel shell in a pattern. The punched and spot-welded areas are called dimples, which create turbulence of the heating or cooling fluid flowing through the jacket. The dimple jacket design allows for thinner vessel shell walls compared to a convention jacket due to the strength of the dimple pattern design.

Dimple Jackets are manufactured in several different pressures and patterns. Apache provides both 12 ga. and 14 ga. material. Each pattern is validated and proof tested per ASME regulations.

Apache has proofed and certified designs up to 1 ¾” at 290psig at 300o F but can go to higher temperatures depending on the application.

Applications and Features

ASME approval by the National Board of Boiler and Pressure Inspectors up to 290 psig.
Pressures of 290 psig with temperature limited to 500 degrees F, depending on the application.
High jacket pressures permitted without significant increase of side structure thickness.
Efficient heat transfer at low media flow.
Dimple jackets are well suited to steam applications.
They can be used to provide heat transfer or cooling for virtually any shape or size of vessel.
On large tanks, dimple jackets have a lower price point and maintain a higher pressure drop compared to conventional jackets. On small vessels, conventional jackets have a lower price point followed by dimple jacket and half pipe solutions.

Apache specializes in manufacturing custom vessels for high compliance industries including pharmaceutical and bio-pharma. We manufacture specialty sanitary design tanks, including pressure vessels, processing tanks and mixing vessels. We have all Stainless ASME certified manufacturing facility with custom capabilities including heat exchange surfaces, agitation, CIP (clean-in-place) componentry and controls. Apache has an in-house quality and compliance team to provide all testing and documentation requirements.

Learn more about Heat Transfer.

Comparing Base, Mid, and High-level Sanitary Finishes [Infographic]

Tue, 31 Aug 2021 21:24:47 GMT

Categorizing levels of sanitary design is helpful to professionals new to compliance regulated industries requiring custom vessels because it bridges communications regarding standards and design requirements.

In hygienic applications, stainless equipment requires a sanitary finish which generally refers to a smooth, scratch-free, non-corrosive finish. The fineness of the finish, which determines its performance, is measured in RA (roughness average). The infographic illustrates the RA of different types of mill, mechanical, and chemical finishes. The smaller the RA reading in microinches (height in millionths of an inch), the smoother the finish.

When collaborating to qualify a project, we define a Base Level Finish as a 2B/Mill, 304 or 316 stainless materials that is pickle passivated. The welds are continuous and crack and crevice-free. This type of finish is paired with a Base Level Sanitary Design and is cleaned manually. Apache’s standard portable vessel line are an example of the base sanitary design and finish level.

A Mid-Level Finish is also composed of 304 or 316 stainless material and involves a secondary process of mechanical polishing greater than 32RA, with final finishing to include pickle or nitric passivation. The welds are continuous, crack and crevice-free, and are also ground flush and polished smooth to a specific RA. Sanitary fittings, mechanical polishing, additional passivation processes and a cleanable design with removable components are categorized as Mid-Level Sanitary Design features.

Providing the smoothest RA readings is an electropolished finish after a series of processes, including mechanical finishing to less than 32 RA, passivation, and nitric passivation, which are common for High-Level Finishes. The base material is 304/316 stainless. The welds are continuous, crack and crevice-free, ground flush and polished smooth to a specific RA designation less than 32RA. The sanitary fittings are also electropolished. Vessels with this level of specifications are typically cleaned automatically.

The specifications, construction and finishing of a vessel is often driven by standards and compliance requirements. All three categories, qualify for ASME UM, ASME U, FDA, 3-A, CRN, PED, BPE.

There are other factors that fall in these base, mid and high-level sanitary design categories, including construction features, processing applications and time to delivery. Download our e-book “Guide to Sanitary Design for Custom Vessels in Hygienic Industries".

Anatomy of a Sanitary Design Vessel

Mon, 30 Aug 2021 15:02:55 GMT

When evaluating a custom vessel manufacturing partner for a new project, consider the manufacturing capabilities and experience that support the vessel’s application and sanitary requirements.

All custom design stainless vessels for the food, life sciences, pharmaceutical and health industries require sanitary construction. It is the application and automation that drives the level of sanitary componentry.

In reviewing each new custom vessel project, Apache identifies the sanitary requirements to categorize the vessel into a base, mid- or high-level design. Apache offers a standard line of vessels that qualify for various regulatory compliance agencies. However, these designs are considered a base level sanitary design, especially because the cleaning of the equipment is manual. Apache identifies a mid-level sanitary design vessel as having COP (Clean Out of Place) components.

In the video, a custom vessel is animated to walk through characteristics and examples in the highest and most automated level of sanitary design custom vessels.

High-Level Sanitary Design Characteristics Include:

CIP (Clean in Place) Process and Components
Continuous, crack and crevice-free welds, ground flush and polished smooth to specific RA (Roughness Average) <32 RA
304 or 316 stainless material, mechanically finished to <32 RA
Electropolished and Nitric passivated finishing
Electropolished sanitary fittings, including:
- Tri-clamp ferrules
- Tube connections
- NA Connects
- Flush mount outlet valves
- Sight glasses
- Orbitally welded j-tubes
- Dip-tubes
- Polished internal coils
- Samples Ports
- Spray devices
- Control panels
- External thermal jacketing

Processes and application in high-level sanitary design vessels include heating and cooling vessels, mixing and processing tanks, WFI tanks, filtering and R & D lab equipment.

Certification requirements is an important part of the sanitary design criteria. Sanitary design standards include:

3A – A regulation of the design for processing equipment in the food and drug industries. A 3A certificate is proof of FDA compliance.

ASME U and ASME UM - A regulation of the design of boilers and pressure vessels, including traceability of materials, procedures, testing and documentation.

BPE – A standard within ASME that drives equipment design for the bio-processing, pharmaceutical and other hygienic required industries.

In qualifying design, safety, automation other application details, Apache will facilitate the required compliance for the vessel and provide well communicated delivery, cost and approvals required for a successful project.

What's Right for my Operation: Pressure v. Vacuum Closures

Tue, 03 Aug 2021 13:17:53 GMT

Vacuum or Pressure closures for small/portable ASME vessels

Many processors come to Apache for a vessel solution in the incubation stage of their business. In some cases, they are looking for help to choose the right kind of vessel that will suit their needs and fit their budget. While Apache provides custom ASME vessels for a range of industries, we also offer a line of standard vessels that often solve what these manufacturers need for their process.

The use of the vessel will determine whether it is a pressurized solution, non—pressurized or vacuum vessel solution.

Vessels that require a minimum of 50 PSI, utilize a pressure closure. Numerous applications, including heating or cooling process, containment, and pressurized dispensing often utilize pressures at or above 50 psi.

It is important to note the safety and ASME requirements for pressure vessels, an ASME UM-mark is required for:

Vessels 5 cubic feet of volume or smaller with pressures not exceeding 250 psi.
Vessel 3 cubic feet of volume or smaller with pressures not exceeding 350 psi.
Vessels 1.5 cubic feet of volume or smaller with pressures not exceeding 600 psi.

For vacuum requirements or non-vacuum applications, such as a storage vessel or collecting vessel, a vacuum closure may suit the application.

In the video, Nick Buchda, Apache’s Small Vessel Representative, demonstrates vacuum and pressure closures on our standard line of vessels.

Apache has produced stainless vessels with ASME certification for over 45 years, with other accreditations for pharmaceutical, life science and health industries including ASME UM, ASME U, FDA, 3-A, CRN, PED and BPE.

Whether the vessel needs fit a standard vessel, modifications to a standard vessel or a custom solution, Apache has the experience to fulfill a range of critical, sanitary-design vessel solutions.

Round Up on ASME Marks

Mon, 02 Aug 2021 20:26:41 GMT

ASME is a leading developer of codes and standards in the mechanical engineering community. These standards enhance public safety and health as well as promote innovation.

The ASME (American Society of Mechanical Engineers) mark is a single certification marketing to signify the international mark of safety and quality. Recognized worldwide, manufacturers that provide ASME have a rigorous quality program, and a third-party review to authorize the use of the mark.

The U mark certifies that the pressured tanks or vessel conforms to the latest edition of the ASME code and that the pressure vessel has been designed and manufactured in accordance with ASME. All aspects are approved by a Third party ASME Authorized Inspector (AAI). U stamps require an ASME inspector to witness the ASME hydro test.

Companies with a U mark undergo a review with the National Board every three years.

The UM mark certified that the pressure vessel or tank conforms to the latest edition of the ASME code and that the pressure vessel has been designed and manufactured in accordance with ASME. The UM vessel’s designation is related to the size of the tank/vessel.

Vessels 5 cubic feet of volume or smaller with pressures not exceeding 250 psi.
Vessel 3 cubic feet of volume or smaller with pressures not exceeding 350 psi.
Vessels 1.5 cubic feet of volume or smaller with pressures not exceeding 600 psi.

While the American Society of Mechanical Engineers writes the rules for the new construction of pressure vessels and tank, the National Board of Boiler and Pressure Vessel Inspectors write the inspection code for new and repaired vessels.

The National Board of Boiler and Pressure Vessel Inspectors require a Certificate of Authorization and R stamp for the repair or alteration of boilers, pressure vessels and other pressure retaining equipment.

Apache has been ASME certified for over 45 years. In addition to ASME, Apache is accredited in many other global standards. By setting parameters for quality and compliance, we offer greater value for our custom stainless ASME tanks and vessels.

12 Engineering Steps to Ensure ASME Compliance for Custom Vessels

Wed, 21 Jul 2021 12:28:58 GMT

Custom vessel manufacturing to industries requiring compliance is what we do. There is a process for customer service and engineering that is required to get the custom vessel you require for your application. There are numerous specifications that will be required based on your process or level of compliance. Apache will work with you to explain and provide options in your vessel project. This collaborative effort will have to control cost and expedite timing for your custom vessel.

Here are our 12 Project Engineering Steps to Ensure Vessel Compliance:

Understand the intent of the vessel. Apache has 45 years of experience manufacturing custom vessels. We can lead important project planning discussion if we know the intent or type of process in which the vessel will be used.
Ensure and Verify Design Conditions. At this step, our project engineers look at the design conditions, process, temperatures, ASME and other compliance requirement and perform initial calculations.
Determine Finish Requirements. Once design is verified and viable, the project is examined for mechanical and electropolishing requirements, as well as access needed for fixtures and how that has an impact on the fittings.
Final Calculations. In this step, the engineer provides final calculations to address issues, verify material thickness and fit of fittings.
Completion of Compliant Design. The ASME/PED/CRN compliant design is completed in 3D Solid Works.
Order long lead time components. The long lead time components such as the mixer, body flanges, heads are ordered. The supply chain is monitored carefully for timing, and any changes are communicated that may affect delivery.
Component Manufacturer Collaboration. Apache leverages long term relationships with component manufactures to customize specifications to meet the needs of the process.
Custom Approval. The customer receives approval drawings with 2D, 3D models. There is often a series of collaborative meetings to finalize the design and approval.
ASME (or other faction) Submission. The final design is submitted for ASME or other compliance agency for approval. Apache also leverages long-term relationships with regulatory agencies to help facilitate a smooth process.
Detailed Drawings. The engineering team completes the detailed drawings for the manufacturing process and fabrication can begin.
Tests / Certifications. ASME tests are scheduled and performed by our Quality Assurance team to comply with the certifications required for the vessel.
Turn-over Packet (TOP). The documentation packet can be completed after the vessel is manufactured and the TOP is developed and uploaded to our customer portal.

Apache’s engineering team articulates technical discussions and is open with timelines, cost and compliance-related issues. Our competence for a pharmaceutical or life science industry vessel is strongly supported in providing all compliance related deliverables.

VIDEO: The Affect of Manufacturing Processes on Stainless Surface Smoothness

Thu, 24 Jun 2021 17:22:58 GMT

The particular RA (Roughness Average) value is a requirement for stainless vessel manufacturing for federal, state or local compliance agencies across many critical industries. It is a crucial standard in these industries to maintain a clean system. The instrument used in the measurement is called a profilometer, which provides an average in micro inches. The smaller the number, the smoother the stainless material. It is common for high compliance vessels to have single digit RA readings on product contact surfaces.

In the construction of pharmaceutical, life sciences, or medical-use vessels, meeting the RA requirement may include several steps, including material selection, grinding, polishing and chemical finishing. Manufacturing processes can affect the RA measurement on stainless material, including forming, stamping and welding. In the video, we walk out of the manufacturing plant with our quality controls manager to show measurements on material in vessels being manufactured in various stages of production.

Pickle Passivation and Electropolishing chemical finishes have a high degree of improvement on RA smoothness compared to material before it is treated. Pickle passivation, also referred to as descaling, removes the scales and leaves a clean matte finish, free from contamination. Electropolishing is an electrochemical process that dissolves surface metal, removing all embedded contaminants and creates a smooth, mirror finish.

ASTM International (American Standard for Testing and Materials) is one of several standards that Apache upholds. ASTM A967 is the standard specification for Chemical Passivation Treatment for Stainless Parts. ASTM B912 is the standard specification for electropolishing stainless steel alloys. The ASME-Bioprocessing Equipment (BPE) standard was created for the pharmaceutical and bioprocessing industry. The BPE surface finish standard classifies surface finishes and the acceptance criteria for compliance.

In the business of compliance vessels, there are numerous standards that are required to deliver the necessary codes in any given project. Follow our videos, blogs and e-books developed specifically to help our processing customers understand the manufacturing and compliance process.

Video: 3 Levels of Sanitary Construction

Wed, 19 May 2021 18:32:20 GMT

Processors serving food or hygienic industries have varying degrees of compliance requirements for custom vessels solutions. The designation of "sanitary" has a wide range of definitions depending on the customer, the industry or the standard.

Since Apache provides custom engineering and manufacturing, we reference these levels to guide conversations so the precise specifications for compliance and function are met. This video is a brief overview how Apache defines base, mid, and high level sanitary vessels.

BASE LEVEL

Apache refers to a base level design as an entry-level, food grade, chemical and general use vessel. Base vessel sanitary construction is typically defined as continuous, crack and crevice-free welds. Fixtures are threaded, such as couplings and dip tubes, an may include ANSI flanges and Thermowells probes. Base level tanks and vessels are pickle passivated and are manually cleaned after use.

MID-LEVEL

In custom sanitary vessel discussions, Apache defines mid-level vessels as COP (clean-out-of-place) capable. There is a higher level of finishing on the inside dimension for mid-level criteria, and the construction fixtures are all sanitary specified, like tri-clamp ferrules, tube connection, NA connects, and sight glasses for example. Processes and applications for mid-level sanitary tanks include columns, solvent tanks, collection, extraction, mixing and dispensing.

HIGH LEVEL

The highest level of sanitary design vessels are designed with CIP (clean-in-place) processes. The finishing on high-level vessels are smoothly polished to less than 32RA (roughness average) on the inside of the vessel. The chemical finish is both nitric passivated and electropolished on high-level vessel designs. Customized high-level sanitary tanks have electropolished sanitary fittings from tri-clamp ferrules, tube connects, to orbitally welded j-tubes, and polished internal coils. Highly compliant and sanitary vessels are used for processing, WFI, R&D lab equipment, heat and cooling, and nutsche filtering.

For more information into the criteria of sanitary vessels, please read "Guide to Sanitary Design for Custom Vessels", a quick-read guide to sanitary standards, construction and the effects on delivery and cost.

Apache Stainless Equipment Corporation is a manufacturer of stainless equipment for a range of hygienic industries, including, food, beverage, biotechnology, pharmaceutical, cannabinoid, and life sciences.

A dedicated quality control and compliance team directs all tests, certificates and documents for all sanitary, ASME, and global standards.

ASME Hygienic Vessel Construction Parameters

Tue, 18 May 2021 17:39:15 GMT

ASME (American Society of Mechanical Engineers) is a leading developer of codes and standards in the mechanical engineering community. ASME code section VIII details mandatory rules regarding vessel design, including engineering, manufacturing, and testing of pressure vessels. These standards enhance public safety and health as well as promote quality and innovation. Here are the main parameters outlining ASME construction of pressure vessels with supporting ASME testing requirements.

Construction
Parameters such as wall thickness, material, and flange rating are determined by the application, including pressure, temperature, corrosion allowance, and fluid flow. These conditions are calculated and reviewed/approved by the ASME inspector when required per code. Stainless, Hastelloy, AL6XN, duplex, and Inconel materials are ASME-approved materials for pressure vessel construction in the pharmaceutical, life sciences, and health-related industries, of which Apache is qualified to fabricate.

Welding
ASME standards also define the quality, type, and finishing of the welds. Head styles (ASME F&D, 80:10, 2:1 Elliptical), seams, nozzles, manways, and other components are designed per ASME Code. Applicable ASME Code welding procedures must be followed using certified ASME welders to maintain the structural integrity of an ASME pressure vessel. Welders must be certified to a qualified weld specification qualified per ASME code guidelines.

Safety Components
Gauges, valves, pressure outlets, and drainage are required safety components in ASME design pressure vessels. The proper selection of components and design is critically important to the safety and performance of the ASME vessel. The selection of safety components needs to be evaluated closely to define the required scope of supply.

Finishing
There is another ASME specification to ensure the quality and safety of parts used in pharmaceutical, bio-processing, and other industries requiring a hygienic vessel, called ASMP-BPE. BPE (Bio Processing Equipment Standard) specifies the surface finishes RA (roughness average) requirements and pickle passivation and electropolishing requirements.

Tests & Certification
There are significant testing, certifications, and documentation requirements for ASME compliance and satisfying the numerous customer requirements. Many require ASME inspection as well as a TOP (turnover packet). Some ASME testing and certification requirements include pneumatic, hydrostatic, liquid penetrant, saline, riboflavin, CIP coverage, material, base metal thickness, material trace, welder trace, Ferroxyl, PMI (Positive Material Identification) radiography, and UT.

Apache has been ASME certified for over 40 years. In addition to ASME, Apache is accredited in many other global standards. By setting parameters for quality and compliance, we offer greater value for our custom stainless ASME tanks and vessels.

How to Evaluate a Custom Pressure Vessel Manufacturing Partner

Mon, 29 Mar 2021 22:13:44 GMT

Accreditations

Custom and pressure vessel manufacturers must have accreditation for ASME certification. Compliance with the National Board of Boiler and Pressure Vessel code is required. Pressure vessel manufacturers must also manufacture to ASME material specifications, certificates, and welding qualifications.

Other accreditations are also crucial in the pharmaceutical, life science, and health industries. Confirm all industry compliance standards, including:
•   ASME UM
•   ASME U
•   FDA
•   3-A
•   CRN
•   PED
•   BPE

Quality Assurance & Compliance

Verify that the manufacturer has a dedicated quality assurance team. There are significant testing, certifications, and documentation requirements for all global accreditation programs. In-house inspection services are a benefit to ASME projects. Review services that should include:
•   Pneumatic testing
•   Hydrostatic testing
•   Liquid Penetrant (Dye Penetrant) testing
•   Saline testing and certificate
•   Riboflavin/CIP (clean-in-place) coverage test
•   Material Test Reports
•   Base metal thickness certificate
•   Material trace
•   Welder trace
•   Ferroxyl test and certificate
•   Positive material identification (PMI) and certificate
•   Ferrite levels and certificate
•   Radiography and analysis
•   UT weld testing and certificate
•   Turn Over Packet (TOP) as required

Experience

The pressure vessel manufacturer must have expertise in the type of vessel and industry experience for the use of the vessel. Critical staff, fabricators, and welders must be ASME certified. All welders must be approved for the weld procedures required to make custom pressure vessels.

Experience and reputation are also significant when developing relationships with inspectors, agencies, and governing officials to keep the compliance process moving forward smoothly.

Service & Support

Above all, assess the service and support provided by the manufacturer. The vessel manufacturer should be able to articulate technical discussions and be open and honest with timelines, cost, and compliance-related issues. Consider other research and questions, such as:

•   Is the proposal easy to understand and compare solutions?
•   Do you have direct access to the engineer for questions?
•   Does the company provide timely and accurate documentation?
•   Does the company offer after-market parts and field service?

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How to Troubleshoot a Pressure Tank

Mon, 22 Mar 2021 19:42:35 GMT

There are several reasons why a vessel may need service, however, two main causes why a vessel may need service are either accident or performance related.

Reduced agitator performance or failure is often due to worn parts, improper assembly or a bent or broken shaft. Agitator repairs may be addressed with the agitator manufacturer or the vessel manufacturer, depending on the situation, down-time, and severity of the failure.

When troubleshooting a drop in pressure in a tank or vessel, a typical cause is often related to seals. One sign of seal failure is product coming out of the seal. To help reduce the frequency of an unexpected seal leak occurring, it is recommended to use a good seal maintenance program to solve a lot of pressure / performance issues, such as:
•   Seal replacement has been neglected
•   Flat spots on seals are a sign for replacement
•   Improper or incorrect seals for the outlet
•   Nicks, scratches or mishandling of seals

A best practice is to avoid product waste and critical down-time is to inventory seals for all outlets and manage seals in a preventative maintenance program.

Depending on the size of the vessel and type of repair, Apache’s service techs may be able to make repairs on site or in some cases, tanks are shipped back to the factory. Apache can provide services including:
•   Field service and troubleshooting to all types of stainless and high alloy tanks
•   ASME / National Board R-Stamp repair and modifications
•   Surface finish repairs
•   Non-code repairs and modifications including piping and heat transfer jackets
•   Seal and agitation repairs and modifications
•   Accessory repairs
•   Head and tank shell repairs
•   Leak detection
•   Audit and service contract available

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