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

Reverse Engineering

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Reverse Engineering

ItalBest Valve has embarked on a revolutionary new project: reverse engineering. Our prerogative is to take on a completely innovative and out-of-the-box approach in the method of valve remanufacturing. Reverse engineering will particularly involve ball valves, both trunnion and floating mounted, while still guaranteeing made in Italy quality.
Our company’s valve repair services will save you time and money. The engineering process behind reverse engineering and remanufacturing would involve existing products, to which new parts and components would substitute old ones. Our company relies on a wide range of high quality materials (metals) to perform reverse engineering and since metals do not deteriorate over time, this would provide for substantial environmental and cost savings. The valve’s trim (Stem, seats, ball, soft parts and seals) would be completely replaced with a new trim, while only the external body and closures would be used.
The body would nonetheless be machined and readapted so that the corresponding valves follow the latest standard and codes. This would imply lower material and employee costs, since it would improve the finished product’s performance and reduce delivery time.  The main purpose is to design a brand-new product as a way to guarantee the valve’s extended life. ItalBest Valve will guarantee 40 working years for these reengineered valves. 
The Company would offer clients a 3 year minimum insurance premium for all of these valves, at the expiration of which a contracted lifetime premium would be provided by means of an advance annual premium. Clients can rest assured of the quality and performance of ItalBest’s Valve, whether original or re-engineered.  Everything will soon be possible, since ItalBest Valve is about to create in Egypt an external manufacturing plant to reduce delivery time and guarantee immediate local assistance for valve both purchased from ItalBest Valve and repaired by the Company itself.

How does Reverse Engineering work?

Design through reverse engineering uses a completely different approach when compared to standard engineering. Using reverse engineering means studying an existing product (of which is not possible to get the original design documents) and analyzing each part of it in order to re-create the original design. From there, specialized engineers redesign from 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 reverse engineering maintenance, the valve(s) you provide to us will be sent to our designated workshop (the closest to the plant in which the valve is installed or stored). Here, it will be disassembled and examined. First, we will perform a few non-destructive tests on the valve’s body and closure, in order to verify and confirm that the components condition is suitable to undergo the reverse engineering process without compromising 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 an argon-filled tank, the material chemical composition will be analyzed and the result will confirm the material’s composition. After PMI, we will perform a Penetrant Liquid or Magnetic test are used to test for significant material cracks. Once we are sure 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,  and its new components will be applied. Valve body and closures will be renewed aour engineers and staff will redesign the valves well. 

Recent standards require only minimal wall thickness thanks to the new technologies which allow for more accurate previsions related to the material’s capability to contain pressure without causing damage. As a result, parts can be cleaned through sandblasting to remove oxidation and then be re machined. A safer solution, when applicable, is to apply a weld overlay before machining, so that the new material is added to reinforce the old one.  Material quality and traceability will be managed according to API and ISO standards, as done for all our products. Additional tests can conducted upon request. Destructive examination can be applied to new components (doing it on body and closure will damage the valve), while for the renewed components we will release the certificate reporting the 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 will include high pressure hydraulic and low pressure gas tests. Any other applicable tests can be conducted upon request.