FAQ for Manufacturing with Forged Components

What is ASME?

ASME is one of the world’s most important boiler and pressure vessel codes. The codes are produced by the American Society of Mechanical Engineers (ASME). ASME is a not-for-profit membership organization so they only exist to help you. The ASME codes were produced to enable collaboration and share knowledge and skills across all engineering areas.

Nearly all of Forged Components’ forged nozzles, forged steel rings, and other custom pressure vessel connections are ASME certified.

What are API blind flange used in conjunction with?

Blinds flanges or “blinds” are typically bolted in place to close off the ends of piping, valves or pressure vessel openings to allow for repeated access. Forged Component is a leading API blind flange manufacturer.

Many of FCI’s custom pressure vessel connections are made with alloy steel. What is alloy steel?

All steels contain carbon and small amounts of silicon, sulfur, manganese and phosphorus. Steels which contain intentional additions of elements other than these, or which exceed 0.60% silicon, or 1.65% manganese and/or 0.60% copper, are termed alloy steels. Forged Components custom pressure vessel connections and forged nozzles are made from alloy steel, carbon steel, stainless steel, as well other materials.

What is Forged Components nozzle estimating tool?

The nozzle Estimation Tool helps the client decide what forged nozzle type they need based on calculations from ASME Section VIII, Division 1 and includes a quote once you choose the type.

Forged Components is known for being a global ASME nozzle manufacturing and pressure vessel connections forging company that meets or exceeds industry specifications. By offering our clients tools such as the nozzle estimating tool we help streamline the process for forging custom pressure vessel connections.

How do I Have Forged Components Design My Custom Flanges?

The first step is to call our sales team at (877) 324-4123. Forged Components is one of the only custom pressure ASME nozzle forging and ASME pressure vessel connections manufacturing companies in America and we got to this level by understanding our client’s needs.

Once our sales department understands your needs, our engineering team will work with your engineering team to obtain the dimensions, specifications and blueprints of the original pressure valve. After the designs are completed and approved, forging begins.

What Type of Long Weld Connections Does Forge Components Make?

FCI has several long weld neck connections, including heavy barrel, intermediate barrel, super barrel and equal barrel. When it comes to long weld neck connection forging FCI shines as the leader in custom cnc machining connections for pressure vessels and carbon steel flange manufacturing. We will forge the long weld connections you need for your project and machines.

In What Shapes Can Forged Pressure Vessels be made?

Forged pressure vessels can be almost any shape, but shapes made of sections of spheres, cylinders, and cones are usually employed. A common design is a cylinder with endcaps called heads. Head shapes are most often round/circular or shaped like a dish. More complicated shapes have been more difficult to analyze for safe operation and are usually far more difficult to construct. That is why one-piece forged vessel components are FCI’s chosen product.

A spherical pressure vessel has approximately twice the strength of a cylindrical pressure vessel. However, a spherical shape is difficult to manufacture, and therefore more expensive, so most pressure vessels are cylindrical with 2:1 semi-elliptical heads or end caps on each end. Smaller pressure vessels are assembled from a pipe and two covers.

I Need a Quote on Pressure Vessel Connections. What is the Best Way to Get One?

The fastest way to get a quote is to complete our simple, online quote form. A sales representative will respond be in touch within 1 to 2 business days.

What Forging and Machining Capabilities Do You Have?

We have over 50 acres of manufacturing facilities including over 300,000 square feet under roof. These facilities include:

  • Our corporate office, main manufacturing and storage facility in Humble, Texas
  • Heavy forge and machining facility in Navasota, Texas
  • CNC machining facility and a Hammer forge and heat treatment facility in Houston

Our forging and machining facilities are equipped with 500-ton, 1,750-ton, 2,000-ton and 3,000-ton open-die hydraulic forge presses; a 14,000-pound open-die hammer; a 300-ton California ring roll; and a wide range of machine tools, including CNC lathes, machining centers, manual VTLs (vertical turret lathes), milling machines, drill presses and saws. FCI can produce open-die and semi-closed die forged shapes weighing from 5 to 50,000 pounds. In addition to the heat treatment furnaces located at the Humble and Navasota forging locations, FCI has added an additional ten heat treating furnaces and both a 16,000-pound polymer and 30,000-pound water quench tank, adding 300,000 pounds to FCI’s heat treating capacity.

What is a Subsea Connection?

A subsea connection is a component used underwater, typically for operations in the petroleum and natural gas industries. Because of the potential for environmental damage if subsea connections are sub-standard, these connections must meet high quality standards established through national and international quality guidelines.

This involves the use of an International Organization for Standardization (ISO)/TS 29001:2010 quality management system specifically tailored for the product and service supply organizations for the petroleum, petrochemical and natural gas industries. This includes any materials, equipment and offshore structures for these industries.

How are Seamless Forged Connections Better Than Those Delivered in Several Parts?

Seamless forged connections essentially merge three parts of a “traditional” forged connection: the pipe, flange, and plate. This simplifies a great deal of operations in the manufacturing process. Seamless forged connections make it easier to manage inventory, reduce the number of parts needed in assembling a project, improves the overall quality of the connection (because there are fewer points of failure in a seamless connection), and can be fabricated faster than fabricating three separate parts.

What Requirements for Pipe Flanges Do I Need to be Aware of?

You need to know the pipe size and, more importantly, the pipe flange fitting standards. Typically, these will be ASME standards, but if you are working with other parts of the world, other standards might be used such as the PN/DIN in Europe, BS10 in the UK and Australia, and JIS/KS standard in Japan and Korea. Make sure that you and your vendor are using the same standards when planning a project.

The composition of the pipe flange is also important depending on what it will be used for. Most pipe flanges used in the petrochemical and gas industries use steel or steel alloys for their flanges.

What Are Blind Flanges?

Blind flanges are used primarily in the oil and gas industries in the construction of pipelines. These are solid walls of metal that are created and machined with one purpose: to completely block off a pipeline so no liquid or gas can flow through. This allows pipeline workers to dam off the pipeline upstream so that blind flange holds back the liquid while they make repairs or expand the pipeline network downstream.

What Are Forged, Seamless Rolled Rings Used for?

Seamless rolled rings are used in a wide variety of industries. From parts in jet engines and turbines and helicopter gearboxes for the aviation industry, to bearings, clutches, drives, gears and couplings in the automotive industry seamless rolled rings are essential components for manufacturing.

Seamless rolled rings are also commonly used in oil and gas production where they are used in forge flanges and pressure vessel connections for pipelines, as well as in fracking and subsea connections.

What is the Difference Between CNC Machined and Forged Vessel Components?

Forged vessel components are created by squeezing metal between two molds: a moving mold called a tool and a stationary mold called a die. CNC machined vessel components use computer numerical control machines with rotating cutting tools to shape a piece of metal, called a billet, into the desired part.

In general, forged pressure vessels are better if you need stronger parts and CNC machined vessel components are better for more complex designs.

What is the Difference Between ANSI and ASME Flanges?

Essentially the measurements used for both ANSI and ASME flanges are identical except in a few rare instances.  For more information about ANSI and ASME, check out our blog post on the topic.

What is the Difference Between Cast and Forged Pressure Vessel Components?

Cast pressure vessel components are created of heating metal until it becomes molten. When metal is in the molten stage it is then poured into a certain mold or vessel that creates the desired shape. Forged pressure vessel components are created when thermal and mechanical energy are applied to steel billets or ingots–while they are still solid–to form a desired shape.

In general, cast pressure vessel components can be made at any size, is less expensive to tool than forging, and can use a variety of alloys to create them. Forged pressure vessel components are much stronger and resists wear and tear better than cast components.

What are the FCI Studding Outlet Manufacturing Standards and Where Do I Get Them?

These are the standards or requirements that must be adhered to during the studding outlet manufacturing process. Check out the FCI Studding Outlet Manufacturing Standards page for more details or check out the FCI-Studding Outlet Specifications page for specific data sheets.

What are Some of the Benefits of Creating Custom CNC Machining Connections for Pressure Vessels?

The biggest benefit of creating custom pressure vessel connections using a CNC machine is speed. Using a CNC is far faster than metal casting or manual machining. Because of the nature of CNC manufacturing, the same model can be reproduced over and over again. CNC Machining also allows maximum flexibility when designing the pressure vessel, as well as allowing engineers to create very detailed and complex parts.

What are Long Weld Neck Flanges Used for?

Long weld neck flanges are used for high pressure and high (or fluctuating) temperature situations primarily in the oil and gas industry. They also serve as anchors for water-mains or sources of gas being pumped into a larger network of pipes, such as those in a factory or in an apartment building. Long weld-neck flanges also are used in situations expansion bends or changes the pipe because of the high pressure.

I’d Like to Come Work for Forged Components. Where Can I Find Current Open Job Postings?

Check out our Career Opportunities page for a current list of open positions.

What Types of Steel Do You Use for Your Pressure Vessel Components?

We maintain a large inventory of bar, billet and ingot materials in carbon, alloy and stainless steel in certifiable ASME, API and ANSI material grades to service customers’ special orders. For specific details, check out our Product Materials page.

Need help getting started with your next project? Let our experts give you a hand.