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12 Engineering Steps to Ensure ASME Compliance for Custom Vessels

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.


What is the Difference Between an ASME U and a UM Stamp?

There are many industry specific certifications in vessel manufacturing that regulate the construction of a vessel. However, for many types of pressure vessels, ASME certification is required and may be in addition to other industry requirements due to the vessel's geometry and pressure designation. Any tank that meets the requirements of ASME Code Section VIII can be certified. This certification is frequently referred to as "stamped" because the code symbol is most commonly applied using a stamp process. Here are the main differences between ASME U and ASME UM symbols and certification.

ASME Certification with U Symbol

  • Any vessel meeting the requirement of ASME Section VIII can be marked with the U Symbol.
  • Most local and state laws require vessel designs 15 PSI and higher to be ASME Code Certified.
  • Qualified manufacturers receive a triennial joint review (audit) by their authorized inspection agency, and the National Board of Boiler and Pressure Vessel inspectors.
  • U vessels require an Authorized Inspector (3rd party ASME inspector) to review with approved calculations.
  • U vessels require an ASME pressure test with the Authorized Inspector residing over the test.
 

ASME UM Symbol

  • UM vessels are smaller in volume (less than 5 cubic feet)
  • UM qualified manufacturers receive an annual ASME review by their authorized inspection agency and are also subject to the same triennial joint review (audit) as mentioned above.
  • UM vessels have size specifications, including:
    •   5 cubic feet of volume or small with pressures not exceeding 250 PSI
    •   3 cubic feet of volume or smaller with pressures not exceeding 350 PSI
    •   1.5 cubic feet of volume or smaller with pressures not exceeding 600 PSI
  • UM Vessels are inspected and tested by a manufacturer's own certified individuals.
 

Note that there may be exceptions to the ASME Certification requirements, depending on your state and local municipality.

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.

Questions? Please call and ask for a Sales / ASME Specialist at 920-356-9900.

 


Small Vessel Scale-Up Solution Quadruples Production

Emerging market start-ups can have production challenges when their business takes off at a faster rate than planned. Here's a problem that Apache helped to solve.

Problem: A fast-growing botanical extraction processor was unable to produce the quantity of product needed to fulfill demand. Their process involved an imported vessel that was placed in a rudimentary ice bath for temperature control. This process resulted in waste of non-consistent product and constant staffing and manual intervention to monitor and adjust.

Solution: Apache's small vessel team provided an ASME processing vessel that completely replaced their batch process. The new vessel was designed with a thermal heat jacket that heated and cooled the product to the exact temperature required for the extraction process. The ASME vessel was jacketed with tri-clamp ferrules and included a site glass and high-pressure sanitary fittings. The vessel has a pickle passivated finish that provides ease of sanitation between batches. 

Apache's vessel runs continuously day and night; it quadrupled production, eliminated product waste and removed employee monitoring and intervention.

Learn more about Small Vessels


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