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.
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:
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.
There are two main causes why a vessel may need service. There is a performance related issue, or there has been an accident.
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.
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:
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
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
Visit Small Vessels
Visit Large Tanks
The ASME R-stamp requirements start with the detail in the code. Summarized from the NBIC (National Board Inspection Code) standards: When a pressure vessel or boiler needs repair, alteration or rerating, an R-stamp may be required by the jurisdiction, or, by the owner / user. When the standard governing the original construction is the ASME code, repairs and alterations to pressure retaining items shall confirm, insofar as possible, to the section and edition of the ASME code most applicable to the work planned.
The 'R' stamp is issued by The National Board of Boiler and Pressure Vessel Inspectors for the alterations or repairs of steam boilers. This certification helps ensure that such alterations or repairs are only done by capable fabricators who can meet the requirements of the code. It is the responsibility of the owner or user of the pressure vessel to secure proper compliance, and work with a certified repair organization and an authorized inspector.
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 repairing.
Alterations and retrofits may also require R-Stamp certification. Experienced certified repair organizations are qualified to determine which elements of the repair or modifications will require R-Stamp certifications.
Our Field Service team is R-Stamp certified. Apache will also provide all compliance addendum documentation required for ASME repairs of modifications in the field.
Depending on the size of the vessel and complexity of the repair, Apache’s service techs may be able to make repairs on site, but in some cases tanks or vessels are shipped back to the factory for repair or modification.
Apache vessel / tank field services: • 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 • Relocate fittings • Re-rating pressures on tanks
Apache's Field Service 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.
Apache manufactures tanks and vessels for compliance and regulated industries, including pharmaceutical, food and beverage, petrochemical, biofuels, chemical and life science. 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.
After 22 ½ years in Apache’s field services group, Bob Dolan is retiring! Apache Stainless is grateful for Bob’s many years of service and sharing his expertise with engineering, sales and customers. Bob recounts some memories through the years with one of his first jobs completing assembly of six tanks (partially built at Apache) in 1996. It was extremely hot with a tight timeline. When the tank arrived, the roof was already off for it and other equipment to be set. The team worked through the night to set and weld the vessel to be out of the way of the day shift millwrights. “I enjoy the work. It is gratifying to help customers and I enjoy meeting people,” Bob expressed. “In the first 18 months, I went from a beginner to a STEP 7 certified welder. After 22 ½ years, I believe I’ve welded and serviced tanks throughout the entire U.S.” “The most challenging job I was on was a tank with a cone bottom. At first sight, it looked like maybe it couldn’t be done. The bottom had to be cut off to get inside. Then I had to service and polish it while hanging upside down. I made a platform to lay upside down, 25 ft. off the floor. That project took one week.” Bob recalls another project where an extremely heavy 32” flange wasn't lining up with the pump. The company had an option to bring in new equipment which would have been costly and time-consuming. Bob modified an elbow pipe leading to the flange that ultimately allowed a perfect fit with the pump. “They didn’t think I could do that one, but we did it. My advice to serving customers and creating solutions is to ‘keep it simple’. Don’t overthink it, most of the time a solution is more cost and time effective for the customer and Apache with a simple approach and customers will agree.” Bob has been a member of the Free Masons for over 33 years. “Free Masons are guided by a code of morals, type of lifestyle, honesty and integrity. I think that it fits in well with the service industry and I’ve tried to do my best to live up to that code.” Bob adds. In his retirement, Bob is going to get to his rebuilding work on the five antique Harley Davidson motorcycles in his home shop. He is planning time for more travel and spend time with grandchildren and great-grandchildren. “It has been rewarding working for a company that holds itself to high standards. I’ve always enjoyed working at Apache and the feeling of self-satisfaction of helping customers. One time, I had a customer say, ‘When I saw you walk through the door, I know everything was going to be okay’.” All of us at Apache Stainless wish Bob a happy and healthy retirement!
Enter your email address to subscribe to this blog and receive notifications of new posts by email.