Meet the “King of Long Weld Necks” Karl Lyons: President of Forced Components, Inc.
Forged Components Inc. (FCI) is the result of Karl Lyons’ 50-year journey in the development and manufacturing of API and ASME pressure-vessel connections. As President and Owner, Mr. Lyons is proud of what FCI can offer its clients by continuously innovating and improving processes to stay competitive and satisfy the needs of the oil and gas industry. With FCI’s dedicated staff or highly experienced “can do” personnel in place to service both existing and new client needs 24/7, our people are trained to follow procedures with employee safety being first and foremost.
“I started working for Lenape Forge in Lenape, Pennsylvania, then known as “King” of long weld necks (LWNs), and was introduced to the concept of forged seamless reinforced nozzles used in pressure vessel fabrication,” explained Mr. Lyons. “I established Forged Vessel Connections (FVC) in 1976 with two partners from Lenape Forge and stayed as president for 11 years. My dream of being the best LWN manufacturer came true as Lenape dropped out of the LWN market. After many ventures in the oil and gas industry, several friends and customers urged me to re-enter the long weld neck nozzle forging business.
I established FCI in 1997 with a dream of becoming the “LWN King” and premier pressure vessel components manufacturer. FCI has invested and reinvested in forging and machining equipment, along with a series of acquisitions over the last 20 years – Humble Forge, Ram Forge, Atex Manufacturing and, most recently, Forge USA assets. The purchase of Forge USA assets brings key synergies to FCI and positions FCI for long term success, allowing us to do all heat treatment in-house for all the forgings produced at our various facilities.”
Headquartered in Houston, the energy capital of the world, FCI is a global leader in forging and machining services, dedicated to ASME and API pressure-vessel components. Operating 24/7/365 and specializing in shutdown/turnaround projects, FCI offers a one-stop source for custom forgings, heat treatment and machining services at seven manufacturing facilities – consisting of four forge shops, three manual and computer numerical control (CNC) machining facilities with extensive machining capabilities, including turning and milling on over 50 acres and a combined 250,000 square feet under one roof, and over 300 employees dedicated to upstream, midstream and downstream finished engineered products. FCI is an open and semi-closed die forging facility capable of producing forgings ranging from 5 to 50,000 pounds using dynamic modular tooling and currently equipped with 500, 1,750, 2,000- and 3,000-ton hydraulic presses, 300-ton ring roll and a 14,000 KGS hammer with in house PMI and Level 3 NDE inspection capabilities.
FCI specializes in manufacturing pressure vessel connections and wellhead components for the oil and gas processing, exploration, petrochemical, and power generation industries. Custom-forged products include blocks, large rolled rings, discs up to 100 inches in diameter, extruded tubes exceeding 120 inches in length, as well as complex shapes.
In addition to an extensive finished product inventory, FCI maintains a raw steel inventory of bar, billets and ingots in carbon, alloy, stainless and nickel alloy steels for ASME, API and ANSI material specifications, along with HF-N (Alky), Chrome Molys (API 934 A, C and E), and very low J and X factors, allowing FCI to offer shorter lead times.
FCI is a vertically integrated one-stop-shop source for forged and finished machined components for the energy industry, supplying quality goods manufactured to ISO 9001 and Pressure Equipment Directive (PED) certifications.
FCI has been successfully listed on most major AML’s – Exxon Mobil, Phillips 66, Valero, Marathon, Flint Hills, Syncrude, etc. – and continuously strives to be listed on other AMLs through its alliance with numerous fabricators in North America.
Check Out Forged Components, Inc. the “King” of Long Weld Neck Flange Manufacturers
We provide custom pressure vessel connections, seamless rolling ring forging, and long weld neck flanges. Give us a call at (281) 441-4088 or contact us online to speak to a long weld neck flange manufacturing expert today.