Forged Components Inc.

Vessel Fabrication Advantages:

The FCI forged connections simplify shop fabrication by “eliminating” the following:
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Reinforcing pad fabrication- layout, cutting, forming, drilling and tapping of weep hole
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Nozzle neck fabrication- layout, cut & bevel pipe/ layout, cut & bevel, form, weld, inspect plate neck
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Component fabrication- fit and welding of flange to pipe/plate or forged cylinder neck
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Reinforcing pad installation- fit and welding of one/two piece pad to vessel shell and nozzle neck
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Inspection & testing- radiographic inspection, UT, PT, MT, air test and other non-destructive tests and inspections as required of components
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Handling of associated components to and from the various work stations
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Inspection and marking of component material- identification/traceability

Improved Quality Control:

Material traceability, component and shop fabrication inspection is reduced allowing Quality Control Inspectors to direct their efforts to other more demanding / critical areas of concern.

In lighter duty applications, the use of Long Weld Necks eliminates/reduces the possibility of barrel distortion that can occur in pipe necks due to heat input from welding.

Cost Reduction Advantages:

The FCI integrally reinforced forged connections reduce fabrication production costs in the following areas:
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Material requisitioning, purchasing and expediting of one part verses three parts (pipe, flange and plate)
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Material handling of only one part into stock and then directly into the final assembly of the work
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Inventory control of fewer parts
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Quality control- traceability, inspection, testing, documentation
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Fabrication schedule reduced thereby improving Purchaser’s deliveries and internal cash flow

Marketing Advantages:

Marketing advantages of utilizing integrally reinforced forged connections:
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Improved and more consistent equipment deliveries to customers due to less variables affecting production
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More consistent pricing of equipment due to estimating of fewer variables
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More competitive pricing a result of being able to use smaller connections for manways and instrumentation connections as FCI forged connection bores are greater than corresponding nominal pipe sizes, e.g. associated connections may be of a size smaller to accomplish the same result
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Increased sales revenue a result of increased production
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Aesthetic appeal of completed work using seamless connections
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Predetermined cost and guaranteed quality level thus assuring on-target performance for the connection portion of the budget
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Special contour forged insert lips, contour forged with aligned grain flow- imparting maximum strength and toughness, can be specified for applications requiring superior resistance to thermal and mechanical stresses