Company Profile
Dear Customer We would like to thank you in advance for the time and the attention that you will give us in reading our company profile. We at PIBIVIESSE, one of the world s leading providers of fluid and gas control solutions, aim to put our deep knowledge in design and manufacture of high-performance on-off and control valves, to the service of our customers and strive to be the most creative and efficient business partner for the energy related industry. At PIBIVIESSE, we are determined to meet and exceed the expectations of our customers and shareholders, in so doing we are committed to the prosperity of the people with whom we do business and that of the countries in which we work. Our work force is motivated and united by shared values and common skills and while adhering to the highest standards of quality and ethics, we will be pleased to provide you with our services, high value-added products and know-how as briefly described in the following pages. Welcome in Pibiviesse The Managing Director
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THE COMPANY Milestones PIBIVIESSE was established in 1981 by three partners, combining the forgemaster expertise with the experience in valve design, manufacturing and marketing. Their vision of the future was to design and manufacture acquisitions of companies with a long experience in machining ball valve components, in order to expand manufacturing capacity. In 1994 Watts Industries Inc. acquired PIBIVIESSE and the new plant of more than 12,000 sq m (132,000 sq ft) covered area was built in Nerviano, about 20 km north-west of Milan, where the head office and main production activities were transferred. A new building of further 3,400 sq m (38,000 sq ft) was added in 1997, to increase capacity for heavy duty state-of-the-art valves designed to perform built to last for the most demanding applications. Their commitment was to follow a total quality concept, from quotation to field service, without any compromise. The Total Quality concept proved to be so successful that the company rapidly became a world-class highly appreciated soft and metal seated valves manufacturer, for many applications in Oil & Gas and other related industries, including Off-shore platforms and Sub-sea applications. In 1985 and 1989 PIBIVIESSE carried out a series of machining and valve assembly. In 1998 CIRCOR International Inc, actual PIBIVIESSE parent company, was spun-off from Watts Ind. A second generation of proprietary technology valves has been introduced in 2000, called CAGEBALL. These revolutionary control valves, designed for extremely difficult working conditions, did set a step change not only in PIBIVIESSE but also in the flow control markets, allowing combinations of valves sizes and flow conditions well beyond industry standards. 4
Our vision of the future Operators in the energy industry are continually requested to increase production, operate at higher pressures, higher temperatures, deeper waters and to deal with increasingly corrosive fluids. The valves which are vital components in the process, are requested to perform critical functions in these demanding conditions. Meeting the highest quality standards and anticipating new and future market demands, our mission at PIBIVIESSE is Engineering the Future, supported by the latest technologies we develop and provide new products tested simulating the working conditions. About 2% of the annual turnover is dedicated to R&D for the development of new products and the improvement of the existing range, implementing the newest technologies so to provide our customers with the most advanced solution at the best value. The Circor Group CIRCOR s business is split in four groups: Aerospace, Instrumentation, Thermal Fluid Controls Products and The Energy Products group. It operates through several manufacturing facilities which are located in the United States, Canada, Europe and the People s Republic of China. PIBIVIESSE is part of the Energy Products group which is among the top three producers of ball valves for the oil and gas markets worldwide and is composed primarily by the following companies: KF Industries; KF Contromatics; PIBIVIESSE; KF Telford Valve and Specialties, Mallard Controls, Hydra seal and SKVC Valve. 5
PRODUCTS & APPLICATIONS Product range PIBIVIESSE designs and manufactures a wide range of high performance manually operable, automated ON-OFF and Control Ball Valves for any kind of fluid handled in the oil, gas, water, steam and power generating industry. The basic ball valve design is of bolted construction style Trunnion mounted ON-OFF ball valves Side entry-bolted body, top entry and fully welded are available with Metal or Soft seats. Specific designs have been developed for HIPPS to SIL3, Sub-sea, Cryogenic, High Temperature, Slurry/Erosive applications in addition to Three-way ball valves and Custom made ball valves. ON-OFF ball valves Sizes from 1/2 to 60 Pressure ratings from ANSI 150 to ANSI 2500-4500 from API 2000 to API 15000 Temperat. range from -196 C (-320 F) to +800 C (+1472 F) Trunnion mounted CAGEBALL control ball valves Specifically designed to handle very high flow rates or very which simplifies field service and maintenance. Our product line is then completed with our top entry ball valves that can be easily serviced without removing the valve from the line and with our fully welded line that is typically used for pipeline/buried application or for sub-sea lines. Trunnion mounted balls permit ease of operation, minimizing the operating torque and reducing seat seal wear. All our products are available in a wide selection of high differential pressures our exclusive and patented CAGEBALL and HYPER CAGEBALL concepts have been integrated with the basic features of our trunnion mounted On-Off ball valves. CAGEBALL control ball valves Sizes from 1 to 60 Pressure ratings from ANSI 150 to ANSI 2500-4500 from API 2000 to API 15000 Temperat. range from -196 C (-320 F) to +800 C (+1472 F) materials ranging from Low Temperature Carbon Steel up to Inconel 625, Incoloy 825 and more. 6
Applications Oil & Gas industry LNG & GTL - Cryogenics Gas transmission and distribution Power industry and steam generation Petrochemical industry Water transmission & desalination plants 7
THE CAGEBALL TECHNOLOGY A proprietary technology After more than 20 years of experience in engineering and manufacturing of side entry and top entry ball valves for severe applications, PIBIVIESSE has developed the most advanced line of rotary control ball valves with the proprietary CAGEBALL design, in accordance with ISA S75, IEC 534. The ball has an integrated patented trim to eliminate or minimize the hydro or aerodynamic flow control disturbances. It is based on a changeable internal cage which divides the pressure drop in stages. The attenuating plates are an integral part of a replaceable cartridge and are offset by an optimally designed angle to obtain a number of significant control advantages, where noise and high frequency vibrations are almost eliminated. This advanced trim allows to control bidirectional flow. The Cage Trim is inserted into a PIBIVIESSE High Performance rugged trunnion mounted valve. Thus all the field proven valve reliability features remain as standard. CAGEBALL control ball valves are particularly recommended any time where noise reduction, cavitation control, erosion, hydrate formation, plugging risk are present or handling of very large flow rates is a challenge for conventional valves. Another important feature is that one and the same valve can do the duty of two or even three valves. Just imagine how potential savings are available in view of building only one automation loop to take care of the application. These control valves product lines can be further personalized with: Integrated down stream Flow Restrictor - Special silencer trim - Expanded flow area in valve outlet for gas flow control 8
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PROJECT MANAGEMENT & ENGINEERING Project management From quotation to field service; this simple sentence means that PIBIVIESSE commitment is to provide its clients with products of the highest quality, ontime at competitive price. Customer satisfaction is our main objective and the same high level of attention is given for any phase of the product life; just from quotation to field service. The Contract Management team is there to work in close co-operation with the client and ensures that each project is accurately defined and planned since the early stages and that the plan is continually tracked during all the design, production, assembly and testing phases. By understanding what the client wants to achieve and what their expectations are, the Contract Management team, coordinating and interfacing with production departments, can help finding the best solutions and fix the basis of a successful project completion in terms of performance and delivery time, while keeping informed on the progresses all parties involved. Engineering the future - Design capabilities PIBIVIESSE is committed to continually develop and manufacture new and better on-off and control valves which will meet the increasingly stringent demands of the energy and process industries. The Company s commitment to Research and Development not only ensures that the most up-to-date technology is used, but also that our clients can count on a reduction of their long term operational costs, due to the long and trouble-free life of our products. We have an unrivalled in-house design capability for safe, reliable and state-of-the-art products. We have developed our own systems, designs and equipment and possess the intellectual property rights and patents for many products and systems. When Research and Development require extra competences, PIBIVIESSE works in cooperation with external research centers and universities, as the Politecnico di Milano, to study on special projects, on materials and on behaviour in critical conditions. Example of this cooperation has been the development of SimOne, our proprietary simulation program for control valves sizing and valve behavior prediction. PIBIVIESSE ball valves are designed in accordance with the industry standards (e.g. API 6D/6A, ASME VIII Div.2, ASME B16.34, BS 5351, etc). For critical applications we make use of FEA based on ASME VIII Appendix 4 recommendations. 10
Process knowledge The company s laboratory has the capability of undertaking all the conventional dynamic and static mechanical, hydraulic and pneumatic tests, together with new tests and new equipment developed in house to simulate more accurately actual field conditions. Special testing facilities: Low temperature: down to 196 C (-321 F) High pressure: up to 160 Mpa (22,500 psi) High temperature: up to 800 C (1500 F) Bending: valve sizes up to 48 900# Slurry loop: sand concentrations to API 14D - API 6AV1 Fire safe: API 6FA, BS6755, API607 Sub-sea simulation: down to 500 m Data acquisition and analysis, using the most modern equipment, provides the basis for continuing research into the dynamic behaviour of the whole valve structure and the influence of each component upon that behaviour. Special efforts have been devoted in predicting and simulating events that may occur especially during the start-up phases Information gained is used both to develop and improve existing components and to develop new ones. of a plant, like overpressures, overtemperatures, external loads, wrong operations and any critical situation that can cause unpredicted stress and therefore damage to the valve. PIBIVIESSE s success stories of thousands of installations worldwide operating in all working conditions greatly helps designers in making profit of the experience gained in practical applications and emergency situations. 11
PRODUCTION Designed to perform, built to last In the production process, every stage is planned to produce quality and the quality is then inspected. The easier a product is to produce, the smaller the risk of defects in production. Simplicity is therefore included as a target in all development and design work at PIBIVIESSE. Production planning also includes the control of documentation at every stage of the process toward the finished product. All this work is designed to enable us to live up to our overall quality target, namely zero defects, because our valves are designed to perform built to last. However, the quality of the finished product is also affected to a large degree by the way production is planned, and by the way in which each individual activity is planned. The operators play a vital role in this area. It is often their know-how, experience and creativity that form the basis of the improvements and simplifications which result in higher, more consistent quality. 12
Sub-suppliers Our sub-suppliers quality is just as important as our own. This means that their quality, and the work they do to improve the level of quality still further, is also a matter of concern to us. We therefore aim to establish long-term and close partnerships with our sub-suppliers. We like to think to our sub-suppliers as partners with a joint aim, nevertheless their performances are monitored and recorded on a regular basis that, combined with our frequent audits, give us the guidelines to enhance and grow the overall products quality and reliability. As a result, we have only selected and quality oriented subsuppliers, to whom we demand to actively participate in our work and thereby develop with us. Raw materials Depending on the application and on the valve function in the plant, a range of base materials are used to manufacture the valve components: Carbon steel and low temperature carbon steel (C-Mn) Low alloy steel (C-Mn-Ni-Cr-Mo) 13Cr and 13Cr/4Ni stainless steel Austenitic stainless steel (series 300 stainless, e.g.316ss) Duplex and Superduplex stainless steel 6Mo austenitic stainless steel Ni & NiCu alloys Ti alloys All raw materials and commercial components of our products, unless clearly identified, are sourced either in Italy or within the European Union. All materials, without exceptions, before entering into our production process are inspected according to our stringent quality control procedures, as dictated in our Quality Control Manual. 13
Machining In-house machining capacity reaches 60 in turning, milling and boring and 72 ball turning and grinding. All these operations are carried out by means of very-high precision machinery and skilled operators, to guarantee the design tolerances (0.01 mm) necessary for the valves to deal with high pressures and high temperatures for many years. Constant attention is devoted to keep all the equipment and machinery at the maximum efficiency level, and the personnel is continuously trained and motivated to make the maximum profit of the advanced technologies used to reach and maintain that high precision and high quality manufacturing needed. PIBIVIESSE valves have gained an optimum reputation on the market thanks also to the high-precision and highquality manufacturing process. 14
Assembly and testing During the assembly operations, all tolerances and matching between parts are accurately controlled, and o- rings/gaskets are inserted in order to ensure perfect and safe seal on body and trunnion. Welding and cladding Welding is another qualifying step of the manufacturing process. The Fully welded valve types are assembled by means of an unique narrow-gap process, that ensures welding of thick materials (up to 300 mm), with a minimum of heat input and therefore without alteration of the metallurgical properties of the base material. PIBIVIESSE ball valves have been subjected to extremely severe special tests, far in excess of the requirements of the API and ANSI Standards. A large number of valves have been subjected to enhanced tests. Special tests such as high pressure N2/He shell and seat test, high temperature leak and operational tests have been performed on customer request by independent laboratories in Italy, UK and Holland. Some high pressure ball valves, of standard Internal cladding with corrosion-resistant alloys is available too and is carried out considering the application and the kind and temperature of the fluid/gas to be processed. trim and design up to 20-1500 lbs size, have been subjected to an extremely severe test program by Soba- Qualitest TUV in Holland. Made by means of submerged arc strip or wire, cladding with High Nickel Alloys is offered as an alternative for those products where solid High Nickel Alloys would make the products very expensive or totally unfeasible. 15
QUALITY & SAFETY Only quality can achieve quality - The Total Quality concept For PIBIVIESSE, succeeding in an increasingly dynamic environment means doing so in the presence of global competitors and with a core technology that is migrating from the industrial western countries to low-labour-cost countries at a very rapid rate. We must combine the core values of Total Quality with the intrinsic entrepreneurial values of creativity, innovation, and diversity in order to develop a renewed competitive edge. More than 20 years in the business have taught us a great deal about fluid control and the needs of different types of customers. This is why we have been able to introduce a vast number of pioneering technologies and solutions. Innovation, of course, is not an end in itself, it is a mean to succeed. That is why we only use proven technologies, components and methods. Our solutions are put through rigorous testing programs again and again. To obtain certifications for us from the world s most prestigious standards organizations is a must. Quality is a mentality which is translated in facts through a rigorous and methodic application of rules and procedures that give clear instructions and measurable results. Incentive programs for On-Time Deliveries and on Non- Conformity reduction, are in place throughout the company and are meant to reward the efforts spent to produce quality all day, every day. Health, Safety and the Environment Totally in compliance with European Regulations, caring about the environment, the health of our personnel and users, is another aspect of quality and an important pillar on which we base our company development. We therefore make a real effort to use non-toxic materials and processes, and also constantly strive to help improve the working environment, and the equipments that are used in workplaces, to protect the people working in it. The overall target is to safeguard our people, the environment and while complying with our customers requirements, to enhance the quality and safety of the workplace in which our products are produced and used. 16
Quality assurance system The high consideration given by management to quality and its control has been one of the main factors to determine the success of PIBIVIESSE. All our manufacturing operations are covered by a quality assurance program, which has been audited and qualified in accordance with: ISO 9001-2000 & API Q1 API 6D - ISO 14313 API 6A - ISO 10423 API 17D ASME sect III PED 97/23/EC ATEX 94/9/EC PIBIVIESSE has been authorised to use the API 6A, 6D, 17D monograms and to manufacture its products with CE logo in accordance with Pressure Equipment Directive 97/23/EC since June 2001. The full production range is therefore available with CE marking and ATEX certificate of conformity. References and approvals PIBIVIESSE has been audited and approved by many of the major worldwide Engineering Companies, Contractors, Oil Companies, Oil and Gas Pipeline Authorities and is supplying valves for many different and demanding service conditions for off-shore and on-shore applications. Please contact our offices for specific references and approvals. 17
GLOBAL PRESENCE PIBIVIESSE s after-sales quality A world of servicing Even if quality is normally associated with the characteristics of our products, our commitment to quality does not end with the delivery, wherever in the world. As PIBIVIESSE sees it, quality is a responsibility throughout the life of our products which also includes the transfer of experience, service and the supply of spare parts to our After Sales Partners in the world. PIBIVIESSE can count on a worldwide valve repair and servicing network to guarantee all of his customers a professional, competent and quick response to any site request. PIBIVIESSE s Authorised Repair Workshops are qualified companies that have been selected in various areas of the world to work on our products and their valve technicians have been trained on PIBIVIESSE products. To ensure that this is the case, we are constantly training our staff in every area of the world, where the lack of knowledge could adversely affect our opportunity to act as support and problem-solvers for our customers. For PIBIVIESSE, quality is not simply the quality of what we do ourselves, it is also the quality of what our customers produce using our methods and products. Dirt, sand, debris, welding slags, rods, sticks, and/or a great variety of foreign matters can be left in the pipeline during construction and the same can become a very serious problem for valves during either commissioning and/or start-up. In case this situation arises we are requested to evaluate and fix the problem as soon as efficiently possible. Personnel that contact the client are qualified engineers with proven field experience and fully trained on our products. Engineering the future to provide products Designed to perform, built to last 18
Pibiviesse valves have been installed in the following countries: Algeria, Australia, Belgium, Brasil, Canada, Caspian sea area, China, Ecuador, Egypt, France, Germany, Greece, Holland, India, Indonesia, Iran. Italy, Kazahstan, Libya, Malesia, Mexico, New Zealand, Nigeria, Norway, Pakistan, Philippines, Portugal, Saudi Arabia, South Africa, South Korea, Spain, Sudan, Syria, Taiwan, Thailand, Turkey, United Arab Emirates, United Kingdom, USA, Uzbekistan, Venezuela, Vietnam
PIBIVIESSE S.r.l. 20014 NERVIANO (Milano) - ITALY - Via Bergamina, 24 Phone +39 0331 408711 - Fax +39 0331 408802 e-mail: info@pibiviesse.it - www.pibiviesse.it