Forged Components Inc. (FCI) products

A flat barrel nozzle is the most common nozzle barrel attachment type that is flat on the bottom (FOB). The FOB design provides the fabricator the flexibility to manipulate the required projection. Another advantage of this attachment type is it presents an option of using an internal projection, if allowed by the design.

A contoured barrel nozzle has the bottom of the barrel contoured to match the ID of the shell or head of a pressure vessel. Based on the customer specified radius and wall thickness of the pressure vessel, our design group will produce a manufacturing print to match that of your pressure vessel. During the fabrication assembly, the nozzle gets inserted into a precut hole inside the shell or head and welded directly to the ID of a pressure vessel, forming a one weld integral connection. This nozzle design does not allow for any internal projection. Although, this is a more expensive alternative to the flat bottom attachment type, it eliminates hours of grinding of extra material to get it flush with the ID of a pressure vessel.

A stub end nozzle as the name implies does not have a flange termination, instead it’s configured with a butt-weld stub end. The nozzle barrel can be supplied flat, contoured or with a Q-lip on the bottom. Once the barrel is welded to the pressure vessel, the fabricator has an option of welding on a flange or pipe to the butt-weld stub end termination.

A studding outlet provides a unique compact design with inherent reinforcement offering distinct advantages to designers and fabricators. The low profile of this connection provides for the lowest projection of a bolted connection where clearance may be a factor in connection selection. The outside diameter and/or body thickness may be increased where additional reinforcement is required. In addition, the studding outlet can be supplied with an optional contoured bottom and/or Q-lip for simplified installation and reduction in cost of positional welding. The studding outlet is the most economical of bolted connections.

FCI specializes in the manufacturing of large diameter flanges produced in accordance with ASME B16.47, Series A & B for sizes NPS 26” to NPS 60” in pressure/temperature rating 75 through 900. Upon request, we manufacture flanges and blinds that are custom-designed to customer dimensional requirements. We have an extensive track record of producing large diameter flanges from a wide variety of material grades. Our extensive raw material inventory allows us to manufacture the flanges to the most challenging customer-specified material chemistry requirements.

A forged ring is known to deliver higher strength and toughness versus the alternatives of castings, weldments or a flame-cut plate. Our 300 Ton ring roller, as well as an open die hydraulic forge press with proprietary tooling, produce seamless rings with a sound internal structure and radial grain flow, resulting in a product with superior mechanical properties, toughness and fatigue strength. FCI’s process also produces excellent concentricity and surface smoothness. Forged rings are manufactured to tight tolerances to meet customers’ specification requirements. Our forged rings are produced to near net shape as forged or rough machined shapes and can be finished to final print dimensions.

A forged block is created through a manufacturing process that involves the shaping of the raw material using localized compressive forces. During the forging process a piece of raw material of the required material grade is compressed with a die till the desired shape of the block is achieved.

A casing head is an adapter between the first casing string and either the BOP stack (during drilling) or the wellhead (after completion). This adapter may be threaded or welded onto the casing, and may have a flanged or clamped connection to match the BOP stack or wellhead. It is the primary interface for the pressure control equipment. When installed, a casing head is typically tested to very strict pressure and leak-off parameters to insure viability under blowout conditions, before any surface equipment is installed.