Methodology

Methodology

PATTERN SHOP

        All casting drawings are verified by the MAGMA simulation software before the process begins. The process is well defined and noted to each department before it starts.

        Gulf valve casting Specialties Pattern shop features highly trained pattern makers from the simple to the extremely complex casting design.The are stored safely after production racked in fully covered area. The total covered area for pattern storage is 2,500 Sq Meters.

        Handling currently 2000 active patterns and can accommodate 2000 more.

Automatic Molding Line

• Our Auto loop Line technology is from by Omega.We are firstin the Middle East to have successfully done auto closing technology for Large Molds of size …….. closing
• Our molding line is equipped with Alpha set no bake process.
• Flask-less molding line pattern bolster size of 1800 x 1600 mm working at a rate of 10-12 molds per hour.
• Continuous Sand Miixer of 45 ton/hour with auto-fill and pattern identificationIRIS program.
• Auto Teach is also included in our system to auto fill the mold to maintain the consistency in every mold.
• IR dryer to dry the new molds before flood coating is also implemented.
• Tunnel drier for mold drying before closing and automatic mold close machine for faster and more precise closing of molds.
• Separate hand molding area for Molding, closing, pouring and cooling.

MELTING SHOP

• Our melting shop designed with three furnaces
• 3000 kg ,2000 kg ,1000 kg with dual track feasible.
• Using our dual track facility, we can deliver up to 6000 kg of molten metal.

Fettling

       Complete fettling set out keeping in view minimum casting movement and linear flow through various stages.

        We are equipped with

• Full Fledged In-house Fettling
• Arc Cutting
• Gas Cutting
• Grinding
• Dressing Facility – Steel Shot Blaster

Heat Treatment

      PLC controlled heat treatment furnaces with paper-less temperature graph recording

• Type: Gas Fired furnace
• No of Furnace: 2 with one water quenching tank
• Capacity: 5ton &12 ton
• Spec: Calibrated to API 6A, API 6D, NORSOK M650

   We have auto quenching with advanced agitator to maintain the water temperature.

Automatic Shot Blasting

      PLC operated 2 nos Shot blasting machines, capacity of 5Tons & 3 Tons respectively with dust extraction system meeting environmental standards.

ACID PICKLING & DP BOOTH

      Complete pickling and passivation facility with a fume scrubber system and imported German material tanks.