Summary:
Synergies Casting Oman is a 2040 vision investment between OIFC (Oman Investment Fund Corporation) and Synergies India.
The mandate was to implement an aluminium wheel plant capable of manufacturing 10 000 wheels per day for the new vehicle automotive market.
Originally scheduled to be operational 4th quarter 2020, Phase 1 was implemented in 2019 with all civil works but was halted during the 2020 Covid Pandemic.
130 individual OEMs on site were planned to install all equipment. Due to Covid restrictions, this was not possible and many OEMs were backlogged post restrictions, which resulted in equipment on site but no installation being performed.
Brief:
Install and commission automated equipment for operation for all sectors and OEM in 8 months, with the first wheel cast in December 2021.
Secondary Brief:
Train Oman local citizens on all aspects of plant operation
Scope:
1.5 production processes: Melting, Casting, Heat treatment, Machining and Paint
2.Automated Integrated Conveyor System
3.Supporting all auxiliary equipment; Chilling Plant, Compressor, Plant, Dust control and Emissions Control, Exhaust stacks, Dust Extraction, and Power Plant
Melting
Existing: Furnace Shell x 4
Activity:
Installation and commissioning of the following:
1.Refractory Inside Furnace
2.Operating Systems with the link up to IT
3.Operating Equipment on furnaces
4,Gas Lines and Ministry Approval
5.Idex Chip \Recovery and Furnace
6.Dust and Heat Extraction System including GTC and Exhaust Stacks
7.Hot Aluminium Receiving Tilting Platform
8.Ingot Machine
9.Degassing/Bleeding
10.Weigh Bridge
Casting
Existing: 20 LPDC Machines on a platform
Activity:
Installation and Commissioning of the following:
1.Integrated Wheel Conveyor
2.Hydraulic Power Packs and Integrated Systems for each LPDC
3.Electrical Supply
4.Gas Supply and Integration
5.PLC Operating Systems
6.High and Low-Pressure Air Supply
7.Robotic Arms for Wheel Feeders
8.Quenching Tanks and System
9.Chilling Plant Supply
10,DE Flashing Machines
11.X-ray Machines
12.Flow Forming Machine
13.Sprue Cutting Machines
14.Wash Plant
15.Zeiss CMM
16.Leak Test Machines
Heat Treatment
Activity:
Installation and commissioning of the following:
1.Heat Treatment Plant
2.Heat Extraction
3.Gas Lines and Integration including a licence from MOH
Integrated Conveyor System
4.Quench Tanks Pre-Annealing
5.Electrical and IT
Machining:
Existing: Building Shell no Ceiling no Equipment
Activity:
Installation and Commissioning of the following:
1.7 cells consisting of 1x CNC machine 1x MC machine and 1x robotic
2.Coolant Cleaning and Refueling System
3.Integrated Automated Chip Conveyor
4.Integrated Automated Wheel Conveyor
5.Temperature-Controlled CNC Machining Enclosure including Aircon and Ceiling
6.5 Ton Overhead Cranes
7.Electrical and IT with Remote Monitoring and Access
Paint Plant
Existing: Building shell and main paint units
Activity:
Installation and Commissioning of the following:
1. Integrated Conveyor
2. All Electrical, Water and Compressed Air Lines
3. 5 Axis CNC/MC Rework Machine
Auxiliary
Existing: zero
Activity:
Installation and Commissioning of the following:
1. Chilling Plant Main
2. Chilling Plant Quenching
3. Compressor Room and Equipment including Ventilation exhaust
4. Emission Controls
5. Store Receiving and warehouse dispatch
6. Gas Certification
7. Fire control systems
8. Cooling Towers
9. Roof extractor fans
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