As a manufacturer of custom vessels for essential industries, including pharmaceutical, life science, and healthcare, Apache provides processors with high-quality vessels with up-front technical collaboration, engineering support, and a solid compliance direction. We bring these 10 tools to Sanitary Vessel customers:
Apache upholds certifications including, 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. In addition to ASME, Apache is accredited in many other global standards.
Depending on the application, processors serving food or other hygienic industries have varying degrees of compliance requirements for custom vessels. When working with your custom vessel manufacturing partner, it is important to identify the level of sanitary compliance in the pre-engineering discovery phase.
Apache defines three categories of sanitary design to help customers with the type of sanitary specifications for construction and fixtures to meet the vessel’s process goals.
BASE LEVEL
The base level sanitary vessel is cleaned manually. Typical construction fixtures include threaded coupling, threaded dip tubes and ANSI flanges. Depending on the application, stock vessels may be used or modified. The material is 2B/Mill, or 304 or 316 stainless and is pickle passivated.
Customers use base-level sanitary vessels for waste tanks, hydrocarbon storage, food-grade applications, adhesives, and solvents.
MID-LEVEL
The type of sanitation is also a driver for more complexity in the design of sanitary vessels. In the mid-level category, components are removed for cleaning or COP (clean out of place).
Mid-Level sanitary vessel designs are constructed with 304 or 316 stainless material and feature mechanical finishing and pickle passivation or nitric passivation.
Sanitary fittings are specified in a mid-level vessel from tri-clamp ferrules and tube connections to NA connects, flush mount outlet valves and sight glasses.
Customers use mid-level sanitary design vessels for material columns, solvent tanks, collection vessels, extraction, expansion chambers, mixing and dispensing.
HIGH-LEVEL
The highest level of sanitary design vessel is automated to be cleaned-in-place (CIP). A 304 or 316 stainless material is specified for high-level sanitary vessels mechanically finished to less than 32RA (roughness average), with nitric and electropolish chemical finish.
The fixtures in this category are electropolished including tri-clamp ferrules, tube connections, NA connects, sight glasses, j-tubes, dip-tubes, and polished internal coils.
Customers using high-level sanitary vessels are involved in automated processing and manufacturing. Applications for high-level sanitary designs include WRI tanks, R&D lab equipment, heating, and cooling vessels and nutsche filters.
Each level of sanitary design can meet ASME UM, ASMEU, FDA, 3-A, CRN, PED, and BPE compliance requirements.
When exploring the project parameters for a custom vessel, our guide, “3 Levels of Sanitary Design Tanks and Vessels” , helps to drive conversations and specifications that will meet the vessel’s application, timing, and compliance requirements.
Apache Stainless Equipment Corporation manufactures stainless equipment for a range of hygienic industries. Apache uploads compliance engineering expertise in beverage, biotechnology, pharmaceutical, cannabinoid, food processing, and life science industries.
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.
There are significant requirements for R-stamp approval including:
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.
Apache Stainless Equipment Corporation, a manufacturer of ASME pressure vessels, was contracted to provide four (4) large columns for a renewable energy company. Apache’s “Large Vessel” fabricators/ welders manufactured four stainless columns that measured up to 167’ in length, 11’ width, and 112,000 lbs. in dry weight.
Government and public opinion will drive growth in the industry, and Apache is poised to support large tank projects with the staffing, expertise, and facilities to manufacture ethanol and biofuel tanks.
Quality & Compliance
We have a dedicated quality assurance department, including in-house inspectors, that focuses on full verification, testing and compliance documentation. Apache has been ASME certified for over 40 years and upholds many other global standards.
Transport
With company owned transport and dedicated employee drivers, Apache provides general and specialized high and heavy load transportation service. We will manage the necessary permits, escorts, and communication necessary for your large tank transport needs.
Field Services
Apache provides experienced and proficient industry technicians and engineering support to troubleshoot equipment repair and provide ASME and R-stamp modifications. Audio and service contracts are available.
Located in Beaver Dam, Wisconsin, Apache Stainless Equipment Corporation serves the fuel industry with many types of specialized tanks, including distillation columns, evaporators, ASME vessels, API-650 vessels, clad vessels, custom mix tanks and storage tanks.
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.
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
In a recent e-book, "Road Map to ASME Submission", we highlighted project engineering steps to ASME compliance for custom vessels, starting with the crucial first step of the customer consultation. The technical sales team learns information about the vessel, the industry, and the process that the vessel will serve. Answers to our inquiries will allow us to recommend design attributes that the customer or engineering firm may not know this early in the design and vessel selection process. This discovery is significant in the absence of a formal specification package.
Essential items that we like to discuss at this stage are:
Fixtures and fittings are also part of the initial vessel project consultation. 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. With this information, we can select the type of nozzle to incorporate and start to pre-plan the general layout and placement of the nozzles. For custom ASME vessels, the nozzles that we use must be compliant-driven and support the pressure/temperature rating of the vessel. Depending on the type of nozzle, we can determine pressure/temperature ratings by performing a proof test or ASME calculations.
When there is an ASME custom vessel expert on one line and a knowledgeable processor on the other line, great results happen. We recently designed a vessel for a customer that incorporated a 22" diameter manway that serves as their vessel's top head.
Using a manway as the top head allows for full access to the inside of the tank for ingredient and component addition and cleaning. This customer explained that ergonomics is critically important to their workforce, specifically when opening and closing the manway. Typically spring assist mechanisms are added to manways to help reduce the effort required to open manway covers. A spring-assist does this well, but it does not provide much dampening while closing or any protection against an operator closing the hinged cover onto their hand. Apache worked with an industry partner to incorporate a new product that uses gas-charged cylinders to reduce the lifting effort to open the manway cover, as well as providing dampening and pinch protection while closing the cover. Incorporating this device into our vessel was quickly approved and very much appreciated by our customer. The vessel's success was a result of starting with the right questions and the right time.
Apache Stainless Equipment Corporation has been ASME certified for over 40 years. In addition to ASME, Apache is also accredited in many other global standards.
Equipment customized to a specific process has its benefits to solve a particular need. With standard equipment, you may need to adjust your scope. It’s understandable that standard stock vessel solutions only solve for a few common applications. However, custom vessel solutions that solve a specific process may take significantly longer to spec out, design and manufacture than standard stock solutions.
Here are tips to help reduce lead times on custom vessel projects:
On occasion, an application may be very close to a standard vessel option. Apache has worked with customers to provide modifications to standard designs that also speed up the delivery of the order. Stock tanks include conventional styles and vacuum applications, ranging from 9” diameter to 18” diameter, and 1 gallon to 37 gallons, with pickle passivated or electropolished finishes. All of Apache’s stock tanks are built to and stamped per ASME code. It is worth considering as a faster delivery option; however not all custom solutions can be achieved by making modifications to the stock vessel designs.
As a manufacturer of custom vessels for essential industries, including pharmaceutical, life sciences, and health industries, Apache works with integrators who add their process technology to equipment and end-users who know their process and need a solution. Conversations around delivery to essential industries are top of mind.
While delivery times are impacted by supply chain, labor shortages, and material availability, Apache will drive the conversation about delivery needs and will consult whenever possible on modifications that help to manage timing for your custom vessel project.
Each province or territory in Canada issues the Canadian Registration Number (CRN) by an authorized safety authority for pressure vessels and fittings that operate at a pressure rating greater than 15 psig. The CRN identifies that the design has been accepted and is registered for use in that province or territory.
1. The first step is to determine what province or provinces the equipment will be operating in. It is important to note that each province or territory has unique application criteria for CRN. If the equipment will be used in more than one province or territory, a separate CRN application is required.
Timing is also discussed early in the project, so customers understand what is involved in the CRN application process. Upon determining the design and shipping requirements, it may take several weeks for the CRN number to be granted depending on the project complexity.
2. Next, approval drawings are developed for specific CRN parameters. Fittings, piping, and components need to be verified through detailed calculations or testing. Further, some provinces and territories require a PE (Professional Engineer) stamp. Documentation for drawings and materials is prepared in accordance with the requirements for the specific provincial CRN application.
3. Depending on the complexity of the vessel, the design verification may require changes and modifications. This involves back and forth consultation with both the customer and the reviewer of the registration.
4. If required, our Quality Assurance team schedules and performs tests to comply with the vessel's certifications and prepares the testing and certification documents.
5. Finally, the CRN number is issued, and equipment only then can be shipped and placed in service.
Custom vessel manufacturing for industries and pressure vessel factions requiring compliance is what we do. There is a process for customer service and project engineering that we follow to get the correct solution with the defined compliance. Apache sales techs and engineers work with customers to explain this process and provide options when necessary to manage your custom vessel project.
Experience and reputation are significant when developing relationships with inspectors, agencies, and governing officials to keep the CRN registration process moving forward. Having exported to Canada for over 40 years, Apache’s small vessel and large tank team have extensive experience with Canadian regulatory requirements and documentation.
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."
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