Category: Ampo Foundry

AMPO FOUNDRY HAS BEEN AWARDED WITH THE LARGEST VALVE CASTINGS CONTRACT IN ITS HISTORY

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A French valve manufacturer has trusted in AMPO FOUNDRY for the manufacture of a significant number of high added value safety valve castings for an important refinery in China, a project that is being executed by a leading Italian EPC. This contract award will be the largest contract ever signed in AMPO FOUNDRY’s 56 years history.

For the development and manufacturing of a total amount of 642 valve body castings and 160 valve piston castings, AMPO FOUNDRY will use its cutting-edge Sand Moulding and Centrifugal Spinning production technologies. In its Sand Moulding facilities, with a monthly production capacity of approximately 340 tonnes, AMPO can produce up to 5 ton castings and on the other hand, in its Centrifugal Spinning facilities, with a monthly production capacity of 450 tonnes, it covers 100-670mm external diameter in horizontal spinning and 430-1200mm external diameter in vertical spinning.

The weight of the valve castings will vary from 24 kgs to approximately 1 ton.

Moreover, some of the valve components will be machined on our brand-new machining facilities, where we have the most intelligent machine tools, together with weld overlay cladding technologies. Furthermore, due to the high criticality degree of those safety valve castings, exhaustive tests will also be performed by approved laboratories in order to guarantee castings’ complete reliability.

The highest technology capabilities and the already proven working experience will enable AMPO to comply with the very demanding lead-time on this project.

Safety valves must provide outstanding performance and exceptional reliability to customers for the most critical and severe applications. Consequently, it is important to count on an integrity foundry’s collaboration. AMPO FOUNDRY is an expert in high added value castings and it has a wide experience in casting development for severe service applications.

At AMPO FOUNDRY customers can find the most updated know-how and engineering services, offering the most reliable high added value castings.

AMPO FOUNDRY HAS COLLABORATED WITH A LEADING SCREW PUMPS MANUFACTURER ON THE DEVELOPMENT OF A NEW SEALED TWIN SCREW PUMP

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AMPO FOUNDRY, an international leader in stainless steel and high alloy castings, has collaborated with a leading screw pumps manufacturer on the complex geometry castings development for a new sealed twin screw pump for chemical and petrochemical sectors.

This new and innovative pump has been recently launched in ACHEMA exhibition and it eliminates the need for mechanical seals and complex seal supply systems, and enable customers to handle harmful substances without polluting the environment. AMPO FOUNDRY has produced high added value castings for this innovative screw pump.

For this project, the parts have been produced in our brand new automated Ceramic Moulding facility. The automation of this process has allowed AMPO to increase its competitiveness, offering a capacity of up to 240 tonnes per month and 60 parts a day.

Moreover, all of the components can also be fully-machined on a brand new 5 axis machining center with FMS (Flexible Manufacturing System).

AMPO FOUNDRY is an international leader in the development of customized and high added value castings for pumps, valves, marine and power generation.

AMPO FOUNDRY PROVIDES PATTERNLESS SERVICES FOR LARGE SAND CASTING COMPONENTS

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AMPO FOUNDRY has developed Patternless Services for the production of large sand casting parts, with a maximum moulding box size of 3000mm x 3000mm, in order to meet customer requirements and continuously adapt to market needs.

This technology has been developed by the Engineering team of AMPO hand in hand with an International Research Centre, as well as with the guidance and the essential contribution of one of its main customers, obtaining an optimum patternless casting method. 

Due to this, AMPO has manufactured by Patternless and Sand Moulding technologies, a 48” butterfly valve body and disc for one of our main global customers.

With this technology there is no need to manufacture wooden patterns. Consequently, it is a very cost-effective way of producing one-off or small production run castings, with the following benefits; lead time reduction, manufacturing cost reduction, high integrity and dimensional accuracy castings, appropriate surface finishes, etc.

In order to offer customers the widest possible range of castings and best solutions, AMPO also has a completely integrated patternless service for small and medium size components within its cutting-edge Ceramic Moulding production line.

At AMPO FOUNDRY customers can find the most updated know-how and engineering services, offering the most reliable and competitive solutions, as well as aftermarket services.

AMPO FOUNDRY WILL SUPPLY AFTER MARKET CENTRIFUGAL PUMP CASING FOR A DESALINATION PLANT IN ISRAEL

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AMPO FOUNDRY is developing together with its customer an aftermarket machined centrifugal pump casing in superduplex (A890 Gr5A) for the largest Desalination plant in Israel.

In the case of pump casings for desalination plants, it is important to consider sea water corrosion and abrasion problems. AMPO’s know how, expertise in special materials and capacity in casting technology, together with customers’ knowledge and experience in sea water pumping has led on the development of the best pump casing solution for corrosive and abrasive services.

Parts will be delivered complete ready for assembly and having in-house technology and being a global supplier has been the key to be chosen by the customer as a partner to develop this project. In this case AMPO FOUNDRY will use its cutting-edge sand moulding facilities, as well as its brand-new machining facilities with the most intelligent machine tools for the production of this casing. Moreover, X-Ray and hydro-tests will also be performed, together with an exhaustive analysis of mechanical properties to guarantee the highest quality level of the casting.

Actually 70% of the drinking water in Israel is sourced by desalination reverse-osmosis technology and the demand for the incoming years will be raising rapidly. Sea water is pumped 24 hours per day and pumps are subject to severe conditions due to the especially high content of salt in the area of Israel. Pump casings and impellers are being periodically replaced causing an increase of operational costs.

Pump casings and impellers must provide outstanding performance and exceptional reliability to customers for the most critical and tough corrosive applications. Consequently, it is important to count on an integrity foundry’s collaboration. AMPO FOUNDRY is an expert in duplex and super duplex steels and it has a wide experience in casting development for severe applications.

At AMPO FOUNDRY customers can find the most updated know-how and engineering services, offering the most reliable after market pump castings.

AMPO FOUNDRY WILL SUPPLY AFTER MARKET HYDRO TURBINE CASTINGS FOR DIVERSE POWER PLANTS IN COLOMBIA

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An international leading manufacturer of hydropower equipment has put trust in AMPO FOUNDRY for the manufacture of machined stainless-steel hydro turbine castings for La guaca and Paraiso power plants, in Colombia.

 

AMPO FOUNDRY will supply approximately 20 hydropower equipment aftermarket castings, such as; covers, caps, rings and shields for beaks. All of them in CA6NM steel and machined.

 

In this case AMPO FOUNDRY will use its cutting-edge sand moulding facilities for large batches and on the other hand, its brand new automated Ceramic Moulding facilities for one-off pieces. For the manufacture of these pieces AMPO will use its Patternless process for rapid prototyping. With this technology ceramic shells are produced in AMPO within a day. The main benefits of this technique are: lead time reduction, manufacturing costs reduction, high integrity and dimensional accuracy castings, appropriate surface finishes, opportunities for one-off and small series production and no pattern storage or maintenance costs.

 

With the latest pattern less casting technologies AMPO FOUNDRY offers aftermarket services to manufacture complete machined components with really short delivery times. Moreover, once the components are produced, AMPO FOUNDRY has an in-house laboratory and the latest NDT facilities in order to ensure total reliability.

 

AMPO team guarantees a prompt response to customer needs wherever they may be; the organization has a clear orientation towards the development of components with short delivery requirements.

AMPO FOUNDRY WAS AWARDED THE SUPPLY OF CASTINGS FOR 30 COKER VALVES

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AMPO FOUNDRY has delivered 30 fully machined casting sets in stainless steel, A217 GrC5 and A217 GrC12 materials to an international leading manufacturer of coker ball valves for refinery applications. In the case of coker ball valves it is important to consider that the embedding of abrasive particles in seat materials can abrade the ball surface and these grooves can then cause leak paths which further damage surfaces. Consequently, the solution is to use metal to metal seating, typically a hard-surfaced ball in nickel-boride or tungsten carbide versus a proven wear surface on the seats (such as Stellite 6). Moreover, the ball sphericity is also critical and that is why it is important to work with a foundry such as AMPO.

In this project, the 30 sets included the most important valve parts, such as bodies, body caps, balls and seats in different sizes and pressure ranges.

Whilst the stainless-steel balls were produced using the Centrifugally Spun process and were precision-machined, ground and hard-coated to a precise and controlled thickness in our brand-new machining workshop.  The seat surfaces and the ball sphere had to match accurately to provide a tight metal to metal seal.

On the other hand, the bodies and the body caps were cast in A217Gr C5 and A217 Gr C12 materials, produced in our cutting-edge Sand Moulding facilities and were also fully machined at our own facility. All of the components also underwent X-Ray and Dye Penetrant Non-Destructive Testing.

Coker ball valves must provide outstanding performance and exceptional reliability to customers for the most critical and tough refining applications, such as erosive and corrosive services, high temperature services, etc.  Consequently, it is important to count on an integrity foundry’s collaboration.  AMPO FOUNDRY is an expert in stainless steel, duplex & super duplex, low alloy and high alloy castings, and it has a wide experience in casting development for refinery applications.

At AMPO FOUNDRY customers can find the most updated know-how and engineering services, offering the most reliable fully machined castings for refining.

AMPO FOUNDRY PROVIDES STAINLESS STEEL & FULLY MACHINED CASTINGS FOR A WORLD LEADING ROTARY VALVES MANUFACTURER

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A world leading rotary valves manufacturer has trusted in AMPO FOUNDRY for the manufacture of finish machined stainless steel castings for its rotary valves. Those valves will be used for food and pharmaceutical applications worldwide.

Rotary valves are one of the most common means of feeding pneumatic conveyance systems, both pressure and vacuum types. There are many other applications where they are used simply for metering of a controlled feed rate. It is a compact mechanical device for continuously discharging bulk powders or granules under gravity flow and it is mainly used for food and pharmaceutical applications, such as in this case.

Common product characteristics, including being sticky, cohesive, corrosive, tendency to “build-up” on the swept surfaces, etc., are compatible with the use of stainless steel with polished or non-stick coated surfaces.

Consequently, all of the castings that AMPO FOUNDRY will supply will be stainless steel parts with excellent surface finish and will be produced using Ceramic Moulding Technology, which enables AMPO to offer large cast components as well as complex geometries, with the best surface finishes.

This moulding technology is moreover highly automated, and this has enabled it to increase its competitiveness.

All the components will be fully machined on a 5-axis machining center with FMS (Flexible Manufacturing System).  AMPO is currently completing the construction of a new 12,500m2 machining workshop in Idiazabal (Spain), where it has invested in intelligent machine tools.  Ampo’s machined components will provide the customer with a significant added value, i.e. a reduction in total cost and delivery lead time, in addition to improving quality control.

 

AMPO FOUNDRY SUPPLIES DISTRICT HEATING VALVE COMPONENTS

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An international leading manufacturer of district heating valves for the entire heating network (from district heating power stations to pumping stations and individual buildings), has put trust in AMPO FOUNDRY for the manufacture of large size (>DN1000) stainless steel and pre-machined parts.

In order to offer customers the widest possible range of castings and best solutions AMPO has four production lines. In this case, for the development of this project, AMPO will use its cutting edge sand moulding facilities and all of the components will also be pre-machined on a 5 axis machining center with FMS (Flexible Manufacturing System). AMPO is currently completing the construction of a new 12,500 m2 machining workshop in Idiazabal (Spain), where it has invested in intelligent machine tools. AMPO’s machined components will provide customers with a significant added value, i.e. a reduction in total cost and delivery lead times, in addition to improving quality control.

The weight of the components will vary from 600 kgs to 1.2 tonnes.

At AMPO FOUNDRY customers can find the most updated know-how and engineering services, offering the most reliable solutions for district energy networks, power plants and internal heating and cooling systems for buildings.

AMPO SIGNS A TECHNOLOGICAL COLLABORATION AGREEMENT WITH CTI

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AMPO and CTI (Castings Technology International) have signed a collaborative agreement whereby CTI will provide consulting services as well as functional advice to AMPO in order to provide higher added value to AMPO Foundry’s customers.

This agreement will help AMPO to continue to offer the most innovative and reliable solutions in the market to its customers, working together with CTI to further the development of several improvement and research lines including Ceramic Moulding, Shaped Centrifugal Castings (SCC), high alloy steels, patternless technology, production of bronze castings, etc.

AMPO FOUNDRY, which is based in Idiazabal, Spain and is a leader in service and the development and production of special material castings, has trusted in CTI due to its knowledge and experience in the development of advanced casting solutions. With this agreement AMPO, foresees a technological leap forward, applying the knowledge and methodology that CTI has previously implemented in sectors such as aeronautics, and optimizing its processes in terms of quality, service and cost.

AMPO FOUNDRY PROVIDES COMPRESSOR CASTINGS

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A European-based American compressor manufacturer has trusted in AMPO FOUNDRY for the manufacture of a significant number of half-finished compressor castings.

In order to offer customers the widest possible range of castings and best solutions AMPO has 4 production lines: Sand Moulding, Ceramic Moulding, Shaped Centrifugal Casting (SCC) and Centrifugal spinning.

For the development and manufacturing of these compressor castings AMPO has used the Ceramic Moulding Technology, which enables the company to offer large cast components as well as complex geometries. This Moulding technology is moreover highly automatic, and this has enabled it to increase its competitiveness.

All these compressor castings have been tailor made in order to meet the requirements of the American customer. In addition to this, it should be noted that for the compressor manufacturer Service was a key factor in this project, and through AMPO’s “patternless” technology, both supplier and customer have been able to fulfill their commitments regarding to delivery times. Few months ago, so short delivery times were unimaginable.