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.
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
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.
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.
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.
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:
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.
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.
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.
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.
An important part of quality assurance is the process of manufacturing a vessel and the completion of required certifications to meet ASME compliance. Equally important is the understanding of these processes and procedures, by all parties from project engineering manager to purchasing teams.
Apache's quality experts have put together a informative resource on factory tests and certifications for ASME tanks and vessels. It is important to have an understanding with customers about what is involved with testing and documentation requirements.
Highlights include:
A review of factory tests Manufacturing process that require reporting An overview of certifications The TOP (Turn Over Packet) Documentation Package
DOWNLOAD EBOOK
Enter your email address to subscribe to this blog and receive notifications of new posts by email.