Reverse Engineering | Ital Best Valve s.r.l.

Reverse Engineering

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Reverse Engineering

ItalBest Valve is proposing itself as the leading company of a new project: reverse engineering. By this definition, the Company wants to open a new way of thinking valves’ world. With this project, ItalBest Valve S.r.l. would like to start a new activity regarding especially ball valves, both trunnion and floating mounted, guaranteeing made in Italy quality of products.  

Repairing service of valves will be a new way to save time and money: the engineering would start from already existing products projecting new pieces that are going to substitute old ones selecting them among a wide range of high quality material. Since metals do not deteriorate through time, reverse engineering’s aim is to project again products in order to use metals.  Trim (Stem, seats, ball, soft parts and seals) will be totally replaced with a new trim, and only external body and closures will be used.
Though, the body will be machined and readapted so that valves follow the latest standard and codes. This would imply lower cost of materials and workforce, since it would improve finished products, and would reduce delivery time because this new engineering would imply a faster delivery rather than a new valve requires.  The main purpose is to design a brand-new product in order to guarantee long life to valves. ItalBest Valve will guarantee 40 working years of them. 

The Company would provide life warranty through a contract which includes an advanced annual payment on expiry of three  year assurance. This will ensure the client complete assurance by buying from ItalBest Valve.  Everything explained above will be soon possible, since ItalBest Valve is about to create outside Italy (Egypt) a workshop so to reduce delivery time and guarantee an immediate assistance for valve both purchased from ItalBest Valve and repaired by the Company itself.

How does Reverse Engineering work?

Design through reverse engineering starts from a total different point of view than standard engineering. Using reverse engineering means starting from studying an existing product (of which is not possible to get the original design documents), analysing each part of it in order to re-create the original design. From there, our specialized engineers re project form the obtained result to develop and design a brand new product, in full compliance with the latest standard revision and the new standard which have been issued since the original valve has been manufactured. 

The aim of the whole process is to re use the external parts of the valve (body and closure), and replace all the trim with new components, in order to ensure a new life of the valve and to restore the pipeline with lower costs, ensure the compatibility between valve and line.  

What will happen to your valve once you decide to accept a reverse engineering maintenance procedure?

Once you decide to undergo to a reverse engineering maintenance, the interested valve(s) will be sent to our designated workshop (the closest to the implant in which the valve is installed or stored), where it will be disassembled and examined. First we will perform a few non destructive tests on the valve body and closure, in order to verify and confirm that the components condition could afford a reverse engineering process without compromising the valve safety. We will check on the material grade using the PMI (Positive Material Identification) Optical Emission Spectroscopy (OES) technique. Using a portable PMI gun connected to a tank full of Argon, the material chemical composition will be analyzed and the result will confirm the composition of the material. After the PMI, we will perform at least Penetrant Liquid or Magnetic test to be sure there are no big crack in the material. Once we are sure a reverse engineering is possible, all the components will be dimensional checked and digitally reproduced in 3D using the FARO technology, a new method which involves a laser to screen the pieces and return their exact dimensions as result. From there, our engineers and staff will re design the valve inside and the new components will be bought. Body and closures will be renewed as well. 

Recent standards requires minor wall thickness thanks to the new technologies which allow more accurate previsions on the material capability to contain pressure without damages. For this reason it will be possible to clean the parts through sandblasting to remove oxidation and re machining it. A safer solution, when applicable, is to apply a weld overlay before the machining, so that new material is added to reinforce the old one. Quality of materials and traceability will be managed as we do for all our products, according to API and ISO standards. Additional tests can be done upon request. Destructive examination will be possible on the new components (doing it on body and closure will damage the valve), while for the renewed components we will release the certificate reporting PMI results.

 Once the valve is assembled, it will be tested to ensure its suitability and conformance to the applicable standards. All the pressure tests applicable on the same valve manufactured ex novo will be performed. Standard pressure tests performed will be high pressure hydraulic and low pressure gas test. Any other applicable test could be done on request.

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