INTRODUCTION: GATE VALVES VS. BUTTERFLY VALVES
In piping systems, flow control is a critical factor influencing efficiency, safety, and maintenance costs. The type of valve used plays a direct role in the overall performance of the system. Two of the most commonly used valves in the industry are gate valves and butterfly valves.
Gate valves operate with a linear motion, opening or closing the flow path completely. When fully open, they provide minimal flow resistance. However, they are often large and heavy, adding extra load to the pipeline and requiring more complex installation.
Butterfly valves, on the other hand, control flow through a rotating disc positioned in the center of the pipe. A simple 90° turn opens or closes the valve, making them lightweight, cost-effective, and easy to install. Their use in place of gate valves has been increasing steadily in modern industries.
WEIGHT AND INSTALLATION ADVANTAGES
Gate valves, especially in large diameters, can be extremely heavy. For example, a DN1000 gate valve can weigh hundreds of kilograms, requiring additional structural supports. This increases both installation time and total project cost.
Butterfly valves of the same size and pressure class are significantly lighter—sometimes by up to 60%. This reduces the load on the pipeline, minimizes the need for heavy lifting equipment, and simplifies handling during installation. Their compact design also makes them ideal for space-constrained environments such as ships, industrial plants, and energy facilities.
COST AND MANUFACTURING EFFICIENCY
Butterfly valves have a simpler construction with fewer components, making them more economical to produce. This results in lower purchase costs, especially for large-diameter applications. Additionally, their lighter weight reduces transportation and handling expenses.
In some large-scale projects, replacing gate valves with butterfly valves can reduce the overall budget by 20–40%. Convalve offers a wide range of materials (cast iron, ductile iron, stainless steel) and sealing options to meet specific application and budget requirements.
QUICK OPERATION AND FLOW CONTROL
Gate valves require multiple turns to fully open or close, which can be time-consuming in emergencies. Butterfly valves, with their quarter-turn operation, can be opened or closed almost instantly, allowing for rapid intervention in critical situations such as leaks or fire hazards.
They also allow for partial opening, enabling precise flow regulation. While gate valves are generally used in fully open or fully closed positions, butterfly valves can operate in intermediate positions, making them suitable for throttling applications.
MAINTENANCE AND DURABILITY
With fewer moving parts and a straightforward mechanism, butterfly valves require less maintenance. They are less prone to internal corrosion or debris build-up, reducing the risk of operational failures.
Convalve butterfly valves are available with EPDM, NBR, Viton, or metal seals, ensuring reliable performance across a wide range of temperatures and pressures. High-grade materials offer excellent resistance to corrosive media, making them ideal for seawater, chemical processing, and high-pressure applications.
LIMITATIONS AND APPLICATION BOUNDARIES
Although butterfly valves offer numerous advantages, there are scenarios where gate valves may still be preferable—such as in very high-pressure applications (PN40 and above) or when absolute zero leakage is required.
It’s also worth noting that, due to the presence of the disc in the flow path, butterfly valves can introduce a slight pressure drop even in the fully open position. However, modern designs and advanced sealing technology have minimized this drawback.
CONVALVE SOLUTIONS AND PROJECT REFERENCES
With over 20 years of experience, Convalve provides high-performance butterfly valve solutions for a wide range of industrial applications. Our products are trusted in projects across Europe, the Middle East, Africa, and Asia.
Real Project Examples:
- Turkey – Thermal Power Plant: DN800 butterfly valves extended maintenance intervals by 35%.
- UAE – Seawater Desalination Plant: Stainless steel, PTFE-sealed butterfly valves eliminated corrosion problems.
- Netherlands – Port Facility: Switching from gate valves to butterfly valves reduced project costs by 28%.
CONCLUSION
Choosing the right valve for a piping system directly impacts efficiency, maintenance requirements, and safety. With their lightweight design, cost savings, fast operation, easy maintenance, and flow control capabilities, butterfly valves present a strong alternative to traditional gate valves.
Backed by Convalve’s expertise and proven track record, our butterfly valve solutions provide long-term reliability and performance in both new installations and system upgrades.