introduction to forged components inc. (fci)...2020/07/08 · tubesheets, custom forgings, wellhead...

Introduction to FORGED COMPONENTS INC. (FCI) Forged Components Inc. (FCI) is a global leader in manufacturing forged integral self-reinforcing connections for the ASME pressure vessels, as well as other commonly used products like studding outlets, heavy wall cylinders, large diameter flanges, tubesheets, custom forgings, wellhead components, power products and subsea fittings. FCI manufactures forged products predominantly for the oil & gas, petrochemical and power generation industries.

FCI was established in 1997 and currently operates from over 300,000 sq. ft. manufacturing area under roof and over combined 50 acres of land. Our current manufacturing sites are as follows:

• Corporate office, full manufacturing and inventory storage facility in Humble, TX • Heavy forge and manual machining facility in Navasota, TX • Small forging and manual machining facility in Porter, TX • FCI Subsea – CNC machining facility in Houston, TX • FCI - Forge USA heat treating and forging facility in Houston, TX - (Forge USA was acquired in June 2017) • FCI – Western of Texas Forge & Flange Co. facility in Kountze, TX – (Western of Texas was acquired in October 2019)

The forging and machining facilities are equipped with 350 Ton, 1,750 Ton, 2,000 and 3,000 Ton open die hydraulic forge presses, a 14,000 pound hammer, 300 Ton California Ring Roll, as well as a wide range of machine tools including CNC lathes, machining centers, manual VTLs, milling machines, drill presses and saws. FCI can produce open die and semi-closed die forged shapes weighing from 5 to 55,000 lbs.

FCI - Forge USA heat treating facility is equipped with API certified heat treating furnaces and 30,000-gallon water & 16,000-gallon polymer quench tanks.

In addition to an extensive finished and semi-finished product inventory, FCI maintains a large raw steel material inventory in the form of bar, billet and ingot. The raw material includes carbon, low alloy, stainless, chrome moly and nickel alloy steels in compliance to various ASME, ASTM and API specifications. Throughout the last 23 years, FCI has invested and re-invested in forging, heat treating and machining equipment to expand its production capacity to stay ahead of our customers’ needs.

In support of its diverse manufacturing capabilities, FCI has established a Quality Management System based on ISO 9001:2015. In addition, FCI has a strong Metallurgical Quality Control program in place. All manufacturing plants are certified to ISO and PED quality systems standards. FCI has an in-house team of ASNT TC 1A certified Level II and Level III technical personnel capable of performing all kinds of non-destructive testing (NDT). FCI performs on-site Positive Material Identification (PMI) on all the finished products. Material traceability is maintained in compliance to EN 10204, Type 3.1 as a default.

Acquisition of Forge USA Additional 90,000 sq. ft. Heat Treating facility with 300,000 pounds of heat treating capacity 14,000 pound Hammer Water and Polymer Quench tanks (NEW) 3,000 Ton open die hydraulic forge press to be installed in Q3 of 2020

Distribution Market • Approved vendors for 2 major distributors in North America DNOW Wolseley Industrial

• Coverage of North & South America through many sub-tier distribution supply houses across US, Canada, and Mexico.

Summary Comments 1. Since the Long Weld Neck (LWN) nozzle falls under the ASME code, FCI manufactures ASME pressure vessel nozzles and

ASME B16.5 & B16.47 flanges of all types, FCI really belongs under the FLANGE category of the AML.

2. FCI operating 24/7 is well positioned to accommodate Shutdown/Turnaround immediate delivery requirements when needed.

3. With 23 Million lbs. of raw steel on-site, complete forging, heat treating, manual/CNC machining and NDE capabilities in-house, FCI can manufacture a variety of components in different sizes and shapes up to 55,000 lbs. for upstream, midstream, and downstream applications.

4. Not only are we able to support your in-house needs on 24/7 basis, FCI in many cases is the sole-sourcing nozzle manufacturer for some

approved ASME pressure vessel fabricators.

5. FCI has a strong design engineering and project management team in place to manage complex projects.

ASME PRESSURE VESSEL DIVISION

TM

END USER - APPROVED MANUFACTURERS LIST (AML)

MIDSTREAM - APPROVED MANUFACTURERS LIST (AML)

ENGINEERING & CONSTRUCTION - APPROVED VENDORS LIST (AVL)

PVF GLOBAL SUPPLIERS

HOLLY FRONTIER

PENDING (AML) APPROVAL

Forged Components Inc. (FCI) is a global leader in the manufacturing of forged integral self-reinforcing connections for the ASME pressure vessels, studding outlets, ASME B16.47 Series A & B large diameter flanges and heavy wall cylinders.

FCI also produces all types of forgings for the oil and gas, petrochemical and power generation industries.

NOVA Chemicals

SAULSBURY

QUALITY MANAGEMENT SYSTEM

Forged Components Inc. Forge USA FC I Subsea Inc.

Humble, TX (Corporate)

ISO 9001 : 2015 ISO 9001 : 2015 ISO 9001 : 2015 ISO 9001 : 2015

Navasota, TX Houston, TX Houston, TX

TM

• Quality Management System is based on the principals of ISO 9001:2015.

• Corporate Quality Assurance function has organizational independence.

• All manufacturing sites are certified to Pressure Equipment Directive (PED) QualityManagement System.

• Metallurgical Quality Control program in place directs selection of raw material heat,

forging and heat treating practices for specific applications.

• On-site NDE department has ASNT - TC - 1A certified Level II and Level III personnel.

• On-site Positive Material Identification (PMI) capability.

• Material traceability and MTRs are in compliance to EN 10204 Type 3.1 standard.

Quality Certificates by Location

PED PED PED

LWN

[email protected] 281-441-4088

“FCI” THE NOZZLE EXPERTSCustom Forging & Machining Services

dedicated to ASME and API products since 1997 with four manufacturing facilities on

40 acres and over 100,000 sq. feet under roof.

FORGED CONNECTIONS FOR PRESSURE VESSELS • Long Weld Necks Connections _______ ___LWN • Heavy Barrel Connections ______________HB • Intermediate Barrel Connections _____ ___I1, I2, I3 • Equal Barrel Connections ____________ __E • Super Barrel Connections ______________SB • Insert Lip Connections ___________ _____Q

ROUGH FORGINGS, CUSTOM PRODUCTS, LARGE DIAMETER FLANGES, STUDDING OUTLETS,

AND BUTTWELD STUB END CONNECTIONS

Inquires: [email protected]

S

“FCI” Pressure Vessel Connections are available in carbon steel, alloy steel, stainless steel and nickel alloys

I2

HB I1

E

I3

I2

HB

LWN

I1

E

TM

46336_FCI_Nozzle_Broch.indd 1 9/4/12 11:00 AM

1750 Ton Press located in Humble, TX

“FCI” THE NOZZLE EXPERTSCustom Forging & Machining Services

dedicated to ASME and API products since1997 with 6 manufacturing facilities on

50 acres, and over 200,000 sq. feet under roof.

24 HOURS / 7 DAYS A WEEK SERVICE

14527 SMITH ROADHUMBLE, TX 77396

PHONE: (281) 441-4088FAX: 1-877-FCI-I123 (324-4123)

OR (281) 441-8899WELLHEAD (281) 441-7728

E-MAIL: [email protected]

Forged Components, Inc. specializes in the forging and machining of ASME self-reinforced pressure vessel connections, API Wellhead products, and flanges. The experience, array of tooling, and equipment within the company promotes custom forged products, machining, and other services as listed below. FCI’s forging and manufacturing capabilities are not limited to the products and/or the material grades as listed. Other forged shapes and complimentary services are provided on a regular basis. Forged shapes can be provided in either the finished machined condition or forged and proof machined for finishing by others.

FCI’s Quality Manual utilizes ASME, API Spec Q1 and the ISO 9000 Program Guidelines in its system to continually monitor the manufacturing processes. FCI connections are manufactured in compliance with ASME section VIII, Div. 1 and ASME B16.5. Products may be ordered to special requirements or other standard codes such as ASME section I and II and Section VIII, Div.2, ASME B 16.47 Series A & B, API and ASTM.

WWW.FORGEDCOMPONENTS.COM

FORGED CONNECTIONS FOR PRESSURE VESSELS• Long Weld Necks Connections _________ LWN• Heavy Barrel Connections ______________ HB• Intermediate Barrel Connections ____ I1, I2, I3• Equal Barrel Connections _________________E• Super Barrel Connections _______________SB

• Insert Lip Connections (Saddle Type) _______Q• Butt Weld Stub Weld Connections• Studding Outlets (Any Connections)• Large Diameter Flanges ASME b16.47 Series A & B• Tangential / Hillside Mount Connection

CUSTOM FORGED PRODUCTS

• Extended Barrel Connections• Rail Car Manway Studding Outlets• Specialty Flow Nozzles• Cylinder and Ring Forgings• Mandrel Rings and Discs• High Pressure Manifold Bodies• Large Diameter Valve Seal Rings• Contour Radius up to 77 _” OD – Nozzles• Open-Die Forgings up to 35,000 Lbs• Bar Products

• API Flanges and Blinds• Wellheads, Casing Heads and Tubing Heads• Tree Cap Body Forgings• Valve Body Bonnets• Spools and Adapters- Drilling Spools and DSA’s• Casing Spools and Tubing Head Adapters• High Pressure Valve Bodies• Square and Rectangular Blocks• Forged Disks up to 95” OD• Elbows & Tees

SERVICES AND JOINT VENTURE FORGED PRODUCTS• Machining Capacity to 144” Diameter• Extruded Headers• Insert (Saddle Type) Branch Connections (Piping Sizes)• Swage Die Forged Bars to 22” OD x 24 ft Long• Closed Die Forged Components

• Reverse Knuckle Cones• Forged Flanges to 14 ft Diameter• Bucket Teeth and other Mining Components• Gear and Crankshafts• Open-Die Forging up to 55,000 Lbs• Overlay

MATERIAL• SA105, SA266, SA336, SA350, SA541, SA182, SB564• Low Alloy Steels, Ferritic – Austenitic Stainless, Martensitic Stainless, Duplex Stainless & Nickel Alloys

• A694, A707, A350LF2• F1, F5, F6, F6NM, F9, F11, F22. F51, F60,F91 • AISI 1029, 1040, 4130, 4140, 4340, 8630• API 36k, 45k, 60k, 75k, (NACE), 110k, (4140)

2012ANNIVERSARY

2012ANNIVERSARY

Celebrating the Past • Shaping the Future

2012ANNIVERSARY

“FCI” The Nozzle Experts

Celebrating Its Fiftenth Year Anniversary 1997 - 2012

46336_FCI_Nozzle_Broch.indd 2 9/4/12 11:00 AM

“FCI” The Nozzle ExpertsCelebrating it’s Nineteenth Year Anniversary 1997 - 2016


1997 2016

• Insert Lip Connections (Saddle Type) _______Q• Butt Weld Stub Weld Connections• Studding Outlets (Any Connections)• Large Diameter Flanges ASME B16.47 Series A & B• Tangential / Hillside Mount Connections

• Extended Barrel Connections• Rail Car Manway Studding Outlets• Specialty Flow Nozzles• Cylinder and Ring Forgings• Mandrel Rings and Discs• High Pressure Manifold Bodies• Large Diameter Valve Seal Rings• Contour Radius up to 77“ OD – Nozzles• Open-Die Forgings up to 35,000 Lbs• Bar Products

• Machining Capacity to 144” Diameter• Extruded Headers• Insert (Saddle Type) Branch Connections (Piping Sizes)• Forged Cylinders up to 160” Length• Swage Die Forged Bars to 22” OD x 24 ft Long• Closed Die Forged Components

• Reverse Knuckle Cones• Forged Flanges to 14 ft Diameter• Bucket Teeth and other Mining Components• Gear and Crankshafts• Open-Die Forging up to 45,000 Lbs• Overlay

• A694, A707, A350LF2• F1, F5, F6, F6NM, F9, F11, F22, F51, F60, F91 • AISI 1029, 1040, 4130, 4140, 4340, 8630• API 36k, 45k, 60k, 75k, (NACE), 110k, (4140)

TM

CUSTOM FORGINGS

Forged Components Inc. | 14527 Smith Road, Humble, TX 77396www.forgedcomponents.com | [email protected] | Ph: 281-441-4088

8630

14527 SMITH ROADHUMBLE, TX 77396

PHONE: (281) 441-4088FAX: 1-877-FCI-I123 (324-4123)

OR (281) 441-8899WELLHEAD (281) 441-7728

E-MAIL: [email protected]

CUSTOM FORGED PRODUCTS• • •

•

••

MATERIAL

•

•

• •

••

• •

••

••

TM

“FCI” The Nozzle ExpertsCelebrating its Twenty Second Anniversary 1997-2019


SA 105, SA266, 336, SA350, SA541, SA182, SB564Low Alloy Steels, Ferritic - Austenitic Stainless & Martensitic Stainless, Duplex Stainless & Nickel Alloys

A694, A707, A350LF2 F1, F5, F6, F6NM, F9, F11, F22, F51, F60, F91 AISI 1029, 1040, 4130, 4140, 4340,API 36k, 45k, 60k, 75k, (NACE), 110k, (4140)

Open-Die Forgings up to 55,000 lbsCylinders / Tubes up to 140” LengthRings Forgings and Disks up to 110” ODMandrel Rings up to 110” ODSquare and Rectangular Blocks (Solid and Punched)High Pressure Valve Bodies

High Pressure Manifold BodiesLarge Diameter Valve Seal RingsValve Body BonnetsSpecialty Flow NozzlesRail Car Manway Studding OutletsBar Products

FCI’s Quality Manual utilizes ASME, API Spec Q1 and the ISO 9001 Program Guidelines in its system tocontinually monitor the manufacturing procesess. FCI’s connection products are manufactured in

and ASME B16.5. Products may be ordered to special

r standard codes such as ASME Section VIII, Div. 1 and 2, ASME B16.47, API and ASTM. requirements or othercompliance with ASME Section VIII, Div. 1

FORGINGS 24 / 7 Current Divisions

FORGED CONNECTIONS FOR PRESSURE VESSELS• Long Weld Necks Connections _______ ___ LWN• Heavy Barrel Connections ______________HB• Intermediate Barrel Connections _____ ___ I1, I2, I3• Equal Barrel Connections ____________ __E• Super Barrel Connections ______________SB• Insert Lip Connections ___________ _____QROUGH FORGINGS, CUSTOM PRODUCTS, LARGEDIAMETER FLANGES, STUDDING OUTLETS AND

BUTTWELD STUB END CONNECTIONS

I2

HB

LWN

I1

E

I3

*

*

* Denotes: ISO 9001 certi�cate applies to FCI Subsea only

TM

FCI IN-HOUSE ENGINEERING IS AVAILABLE TO ASSISTYOU IN FORGING DECISION, MATERIAL SELECTION, AND CUSTOM FORGED PRODUCT DEVELOPMENT.

Forged Components, Inc. Corporate Office located at 14527 Smith Rd. Humble, TX 77396 Inquires: [email protected] Customeer Service: (281) 441-4088 Fax: (281) 441-8899 Website: www.forgedcomponents.com

100 year old, newly renovated 3000 ton press

FORGED POWER PLANT PRODUCTSHeavy wall �ttingsLateralsWyesForged and bored pipeTees

Reducers CapsVenturiSpecial designed �angesHeavy Barrel Necks

•

• • •

• • • • • •

FORGINGS 24 /7 - Power Products Division

TM

POWER PRODUCTS

POWER PRODUCTS CUSTOM FORGED AND FINISHED MACHINED

TEESWYESLATERALSPIPE CAPSREDUCERSVENTURIS

HEAVY WALL

Forge USAA Forgings 24/7 Company

FCI ACQUIRED ASSETS FROM FORGE USA IN 2017

Chambersburg 14,000 lb Hammer Press

Complete Heat Treating Facility with 30,000 lb capacity

Water Quench Tank 20,000 lb Capacity

Polymer Quench Tank 16,000 lb Capacity

Sawing Capacity with 3 saws up to 40”

Fork Lift capacity up to 55,000 lbs

Additional 90,000 sf under roof

[email protected]

Phone:(713) 863-9933

[email protected]

Phone:(281) 441-4088

Servicing the Oil And Gas Industry Since 2001

TM

Read BIC Magazine online at BICMagazine.com May 2018 103Follow BIC Magazine on and

[email protected]

281-441-4088

With over 20 years of experience manufacturing pressure vessel components, Forged Components Inc. gets the job done right 24/7/365, providing emergency service for all shutdown & turnaround engineering projects.

FCI operates 24/7/365, specializing in shutdown-turnaround projects and offering a one-stop source for custom forgings, heat treatment and machining services dedicated to ASME and API products since 1997, with 7 manufacturing facilities on 50 acres and over 250,000 sq. ft. under roof; ISO, PED and ABS certifications; an extensive raw steel inventory of carbon, alloy, stainless and nickel alloys, along with HF-N (Alky) and Chrome Moly’s (API 934A, C & E) - very low J and X Factors.

“ALL OF THE ABOVE ENABLES FCI TO OFFER SHORTER LEAD TIMES”

FACILITY EXPANSIONS BRING FORGE MANUFACTURING LEADER NEW CAPABILITIES

HUMBLE, TEXAS (CORPORATE OFFICE) PRESSURE VESSEL FAMILY NAVASOTA, TEXAS FACILITY

[email protected]

281-441-4088

With over 20 years of experience manufacturing Pressure Vessel Components Forged Components Inc. gets the job done right 24/7-365 providing Emegency Service for all shutdown & turnaround

engineering projects.

FCI-operates 24/7-365 specializing in Shutdown-Turnaround projects offering ONE-STOP source for Custom Forgings, Heat Treatment and Machining Services dedicated to ASME and API products since 1997 with 7 manufacturing facilities on 50 Acres and over 250K Sq. Ft. under roof. ISO, PED and ABS certifications, extensive raw steel inventory of carbon, alloy, stainless and nickel alloys along with HF-N (Alky) and Chrome Moly’s (API 934A, C & E) - very low J and X Factors.


Corporate Office14527 Smith Road, Humble, Texas 77396

Canada Sales OfficePh 780-905-6180 Fax 780-462-7471

FCI YOUR FIRST CHOICE IN QUALITY FORGED PRODUCTS

Additional 90,000 sq ftfacilityHeat Treating FacilityForged Hammer 14,000Kgs1,500 Ton HydraulicPress Being installed

Box and car bottomfurnaces.Total weight capacityover 300,000 Lbs.Quench tanks and polymer tanks.

LWN

I-2

HB I-1

E

I-3

HUMBLE TEXAS (CORP. OFFICE) PRESSURE VESSEL FAMILY NAVASOTA TEXAS FACILITY

A FORGINGS 24/7 COMPANY

3000 TON PRESSACQUISITION FORGE USA FORGE USA HEAT TREAT CUSTOM FORGINGS RAW STEEL INVENTORY

Forging weight from 5 to 50,000 lbs.Disc up to 100” O. D.Extruded Tubes up to120” LTH.ISO/PED/ABS Certified

Raw Bar/Billet/Ingoton site inventoryCarbon Steel, Alloy, S. Steel HF (Alky) &Chrome Molly APILargest inventory ofFinished LWN items.


· Additional 90,000 sq. ft. facility· Heat treating facility· Forged hammer 14,000 kgs· 1,500 ton hydraulic press being installed

· Box and car bottom furnaces· Total weight capacity over 300,000 lbs.· Quench tanks and polymer tanks

· Forging weight from 5 to 50,000 lbs.· Disc up to 100” O.D.· Extruded tubes up to 120” LTH· ISO/PED/ABS Certified

· Raw bar/billet/ingot on site inventory· Carbon steel, alloy, S. Steel HF (Alky) & Chrome Molly API· Largest inventory of finished LWN items

ACQUISITION FORGE USA FORGE USA HEAT TREAT 3,000 TON PRESS CUSTOM FORGINGS RAW STEEL INVENTORY


FCI: YOUR FIRST CHOICE IN QUALITY FORGED PRODUCTS

Canada Sales OfficePhone 780-905-6180 Fax 780-462-7471

LWN

I-2

HB I-1

E

I-3



[email protected]

281-441-4088






[email protected]

281-441-4088










LWN

I-2

HB I-1

E

I-3















LWN

I-2

HB I-1

E

I-3



[email protected]

281-441-4088






[email protected]

281-441-4088










LWN

I-2

HB I-1

E

I-3















LWN

I-2

HB I-1

E

I-3


introduction to forged components inc. (fci)...2020/07/08 · tubesheets, custom forgings, wellhead...

Documents