How to Lower TCO of your Butterfly Valve

How to Lower Total Cost of Ownership (TCO) of Your Butterfly Valve

How to justify the upfront cost of high-performance butterfly valves and optimize their use and operation in your piping applications to maximize their cycle life

A high-performance butterfly valve is a relevant capital expenditure. Simple in operation, yet important to keep the system running. This industrial valve is like a faithful wife to a turbine/compressor – regulating, throttling and managing the pressure and fluid flow to keep things abay. 

A butterfly valve and its actuator play the tough role of balancing loads so other relevant equipment will not be easily damaged.  It now becomes a challenge for an engineer or a purchaser to procure the best type of butterfly valve from the most trustworthy butterfly valve manufacturer

If you are looking into optimizing your butterfly valve and maximizing every dollar you will spend on it, you’ve come to the right place! 

As someone who has actively participated in the maintenance and operational aspects of mechanical systems, I’ve gained invaluable insights into the optimization of industrial components like butterfly valves. My role involved a range of responsibilities from preventive maintenance to assisting in electrical system troubleshooting, allowing me to understand the nuances of efficient valve operation and maintenance. This experience has been instrumental in shaping my approach to reducing the Total Cost of Ownership (TCO) of butterfly valves

– Author

In this guide, I’ll discuss ways on how you can lower your cost of butterfly valve ownership so you can efficiently max out your investment costs, and how to find a butterfly valve supplier that will sustain what your piping installation needs.

What is ‘Total Cost of Ownership for Butterfly Valves’?

Total cost of ownership (TCO) for butterfly valves is a proven technique of summing all costs related to buying butterfly valves and considering associated fees during its entire lifetime. We’re talking about not just the upfront investment, but also its opportunity costs, manufacturing process, quality, spare parts costs and even maintenance and operation costs over its entire service life. 

Why it’s Worth for Your Company?

To be frank, it’s worth every dollar you spent on a butterfly valve, especially the high performance, heavy-duty, industrial type. Even though butterfly valves costs way lesser than gate valves, you wouldn’t want to waste money on choosing a valve, a valve supplier or a service provider that isn’t worth it, right?

TCO is an intricate process, yet yields high returns to your company at faster ROI returns. But it’s a sad story that many companies are not taking measures to follow it religiously. If you want long-term benefits with dramatic yields, then it’s time to act and transform your project and operations to lower TCO.

Everyone Plays a Role

For an engineer, choosing the right type of butterfly valve for complete optimization is a challenge. For a purchasing manager, it is looking for a reliable butterfly valve manufacturer to negotiate with

What are the Things You Should Look Into to Optimize Costs?

#1 Select the Right Type of Butterfly Valve for Your Specific Application

Choosing the right type of butterfly valve is one of the most important ways of lowering your TCO. High-performance butterfly valves are classified according its end connection style, seat design, body material and offset design. Each type can be operated and installed differently from each other. 

We covered a comprehensive guide on butterfly valve types on another article, in case there is some confusion on which type to use.

Pressure is Key to Selection

Logically speaking, if you want to optimize your system and reduce costs of operation, you must consider what influences its gain or loss. For butterfly valves, the main thing is pressure. 

Pressure is accounted for butterfly valve selection and sizing. Sizing your butterfly valve wrongly can incur huge losses in a pipeline, as compared with gate valves. Thus, when sizing, we need to take into account the pressure on the butterfly valve disk to withstand the pressure of the pipeline. 

Choose a supplier that has the expertise in manufacturing butterfly valves for high pressure and high temperature applications.

#2 Make Sure that the Seat Material and Disc Offset Design are Right for its Intended Application

Seat material and offset design are not just important considerations for shut-off operations, but specifying the right type can determine the longevity of your butterfly valve. 

Butterfly valves with plastic linings are usually with concentric designs. These valves are used where seat leakage is not much of a concern. For seats with metal or rubber linings, they are either double offset or triple offset butterfly valves. While double offset designs are perfect for flow control applications, triple offset valves can be used for tight shut off applications.

Handling difficult fluids such as abrasives can be challenging for a zero offset butterfly valve seat. For this application, you can use double offset or triple offset valves. The wrong choice of valve seat design and material can result in a lot of system downtime.

#3 Select the Appropriate Mode of Operation

Choosing the right type of actuator for the butterfly valve plays a vital role in reducing cost of operation. As you know that a pneumatic actuation for valve is more expensive and reliable than a manually operated valve, but you can never go wrong with its overall performance. It’s more accurate and safer for fluid regulation, control and throttle. 

If you want to lower cost of ownership, consider the long term benefits of each type of actuator for your butterfly valve. There are different standards you can refer to, but for hazardous applications which is most common in industrial plants, the NEMA compliant actuators are the most suitable. Electric controlled or pneumatic valve actuators are also feasible not just in terms of its cost effectiveness, but also for safety reasons.

We have also covered a review on how different actuators work for butterfly valves to give you further information on which mode of operation is best for pipeline optimization.

#4 Optimize Maintenance Schedules

The greatest influx of money spenditure roots from dedicated periods of plant maintenance. Plant turnarounds, outages and shutdowns require an ample amount of time to stop plant operation for maintenance purposes. 

Plant outages should speed up return on investment (ROI), enhance production quality and meet and improve the overall KPI. Since costs are high (cost for manpower, downtime and equipment), unplanned maintenance due to repairs is a downside for a company. Hence, you should systematically plan out and follow preventive maintenance schedules to prevent future issues caused by downtimes.

#5 Optimize Spare Part Inventories

As the Plant’s Maintenance Manager, some of the ways you can optimize your spare part inventory is to make a comprehensive planner that can be easily understood by your team, conduct monthly inventories and update your BOM. A systematic language for all your maintenance team members can ensure maximized productivity where you can readily acquire spare parts whenever you need them.

#6 Inspect the Quality of the Butterfly Valve

When it comes to outsourcing butterfly valve manufacturers overseas, some manufacturers may offer low price but the product’s integrity may be questionable. For considering TCO of butterfly valves, one should focus more on the quality than price. 

In order to know if you are picking the right butterfly valve manufacturer with high quality products at a reasonable price, you must audit their QC procedures, standards, certifications and manufacturing methods.

It is also highly recommended that you visit the manufacturer’s facility to do field inspections. Remember, you must also be vigilant and keen on manufacturing practices. Valves may pass initial quality standards but end up losing its quality at an earlier span of time. It may be attributed to the way they weld the valve body, feed the valve into the oven, or how thick coatings are applied.

As an expert high performance butterfly valve manufacturer, we have stringent QC procedures and intricate manufacturing techniques. We produce high quality valves with robust construction and longer cycle life, which can surely lower your TCO.

#7 Choose the Right Butterfly Valve Supplier

You can find reliable manufacturers of butterfly valves but it’s highly important that you know how to source them out and audit their manufacturing processes. First is to gather all raw data on what each manufacturer offers. This includes prices and services. Then you can assess the weight of each aspect to the needs of your pipeline system.

Finding the right butterfly valve supplier which considers the TCO aspects is a difficult task but can yield you many monetary benefits. 

Things to consider?

  • Cost of shipping and sometimes, re-shipping
  • Opportunity costs and incurred incentives when an alternative is presented. 
  • Tax credits, customer-oriented company visits. 
  • Other tools and services rendered to invoke purchase decisions.

What’s the Bottom Line Impact?

When you religiously follow the above methods, there’s no doubt you can significantly lower your total cost of butterfly valve ownership. In turn, this can render you with millions of potential savings annually. This also permits less costly operations and maintenance for your company.

Wrapping Up

Often times, the relationship between the butterfly valve manufacturer and client can highly influence the success of your plant operations.

To lower your TCO, we can help you select the best high performance butterfly valve for your application. Find a supplier who can provide guardian support during installation, operation and maintenance.

If you also need pertinent information for your purchase-justification where you need to justify a replacement of your butterfly valve, we’re here to support you. For more information, you can contact us through our website and we’ll be in touch.

Noelle-Nicole-Go-SEO-Expert,-Manufacturing-Specialist

Noelle Nicole Go

MECHANICAL ENGINEER, BUSINESS OWNER

Noelle has over a decade of experience in the product design and development industry. She has extensive knowledge in the supply chain industry being an importer and business owner herself. Her passion has always been in machines, construction, and sharing her knowledge with other entrepreneurs.

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