• Inadequate Sealing at Low Pressure: Butterfly valves rely on the disc pressing against a soft seat for sealing. At low pressure, the force may not be sufficient to create a perfect seal, leading to potential leakage.
• Wear and Tear of Seals: Over time, the seat material (usually rubber or PTFE) can degrade, especially in abrasive or high-cycle applications, causing leaks.
• Misalignment of Disc and Seat: Improper installation or misalignment can prevent the disc from fully sealing, resulting in leakage.

Solution:

• Use high-quality seat materials and ensure proper alignment during installation. Regular maintenance can extend seat life.

2. Limited Throttling Capability

• Butterfly valves can control flow, but they are not ideal for precise throttling. Partial disc openings may create turbulence, vibration, and cavitation, potentially damaging the valve and pipeline.

Solution:

• For precise flow regulation, consider globe or control valves designed specifically for throttling. Use butterfly valves primarily for on/off applications.

3. Disc Obstruction and Pressure Drop

• The disc remains in the flow path even when fully open, causing a slight obstruction that can lead to pressure loss and turbulence. In high-velocity systems, this can reduce efficiency.

Solution:

• Opt for larger valve sizes or high-performance designs (such as double-offset or triple-offset butterfly valves) to minimize disc interference and improve flow characteristics.

4. High Torque Requirements

• Larger butterfly valves or those operating under high differential pressures may require significant torque to open or close, especially if the valve has not been operated for a long period. This can lead to actuator wear or mechanical failure.

Solution:

• Use gear-operated or actuated butterfly valves to reduce manual effort and ensure smooth operation under high pressure.

5. Cavitation and Vibration

• In high-pressure systems, rapid closure of the disc can cause cavitation (formation of vapor bubbles), leading to vibration, noise, and potential erosion of the valve components.

Solution:

• Avoid sudden valve closures and select high-performance butterfly valves that are resistant to cavitation.

6. Erosion and Corrosion

• Butterfly valves used in harsh environments (chemicals, seawater, or abrasive media) are prone to disc and body erosion or corrosion over time. This can weaken the valve structure and lead to premature failure.

Solution:

• Choose corrosion-resistant materials (stainless steel, bronze, or PTFE-lined valves) based on the specific media being handled.

7. Temperature Limitations

• Soft-seated butterfly valves (EPDM, NBR, etc.) have temperature limitations. Excessive heat can deform the seat, while extremely low temperatures can cause brittleness.

Solution:

• For high-temperature applications, use metal-seated butterfly valves or triple-offset designs, which can withstand extreme temperatures.

8. Potential for Water Hammer

• Rapid valve closure can result in water hammer, causing pressure surges that may damage the valve or pipeline. This is common in fast-acting automated systems.

Solution:

• Implement slow-closing actuators to prevent water hammer. Use dampeners or bypass systems to control pressure surges.

9. Limited Suitability for High Differential Pressures

• Standard butterfly valves may not perform well under high differential pressures, leading to disc deformation or operational difficulties.

Solution:

• Use double-offset or triple-offset butterfly valves, which can handle higher pressures and provide better sealing performance.

10. Installation Challenges

• Misalignment during installation can lead to improper sealing and increased torque requirements. Additionally, wafer-style valves require precise gasket placement to avoid leakage.

Solution:

• Carefully follow installation procedures, ensuring the valve is centered properly between flanges. For critical applications, consider lug or flanged butterfly valves for easier installation.