Apache Stainless Blog

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:

1. 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.
2. 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.
3. 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.
4. Final Calculations.  In this step, the engineer provides final calculations to address issues, verify material thickness and fit of fittings.
5. Completion of Compliant Design.  The ASME/PED/CRN compliant design is completed in 3D Solid Works.
6. 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.
7. Component Manufacturer Collaboration.  Apache leverages long term relationships with component manufactures to customize specifications to meet the needs of the process.
8. 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.
9. 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.
10. Detailed Drawings.  The engineering team completes the detailed drawings for the manufacturing process and fabrication can begin.
11. Tests / Certifications.  ASME tests are scheduled and performed by our Quality Assurance team to comply with the certifications required for the vessel.
12. 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.

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?

Download Small Vessel brochure
Download Large Tank brochure

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