In industrial piping systems, high-temperature and high-pressure conditions have always placed stringent demands on valves. Traditionally, gate valves and ball valves have been the mainstay in such environments, offering reliable sealing performance and pressure-bearing capacity. With advances in valve materials and structural design, however, an increasing number of companies are now asking:

 

Can butterfly valves serve as an alternative to gate or ball valves under high-temperature, high-pressure conditions?

 

This article provides an in-depth analysis of valve structure, sealing characteristics, material selection, and practical application cases, helping engineers make more informed decisions during valve selection.

 

 

1. Why Are Gate and Ball Valves Traditionally Preferred in High-Temperature, High-Pressure Applications?

 

1) Gate Valves: Strong Pressure Capacity and Reliable Metal Sealing, Ideal for Fully Open or Fully Closed Operation

Gate valves use a wedge-shaped gate structure, providing high compression force and reliable metal-to-metal sealing.

They are suitable for critical applications such as steam systems, refining units, and high-temperature oil services.

Their robust design resists erosion, making the sealing surfaces less prone to damage from high-velocity media.

 

2) Ball Valves: High Sealing Performance, Easy Operation, and Excellent High-Pressure Resistance

The floating or trunnion-mounted ball structure allows ball valves to maintain tight sealing even under high pressure.

Metal-seated ball valves can operate at temperatures exceeding 425°C.

Quick opening and closing make them suitable for systems requiring rapid shut-off.

 

Therefore, under extreme operating conditions, gate and ball valves are generally considered the more stable and safer choice.

 

 

2. Why Are Butterfly Valves Being Considered as Alternatives?

 

With advances in materials and manufacturing technology, butterfly valves, especially triple-offset metal-seated butterfly valves (TOBV), have seen significant performance improvements, giving them a competitive edge in high-temperature, high-pressure applications:

 

Metal-seated design can withstand high temperatures (typically 425°C–600°C, depending on materials).

Torque-seated design allows the disc to close against the sealing ring without friction, reducing wear.

Lighter weight, more compact structure, lower cost, and smaller installation footprint compared to gate and ball valves.

 

As a result, engineers are increasingly evaluating whether butterfly valves can replace gate or ball valves in certain high-temperature, high-pressure conditions to reduce costs and maintenance complexity.

 

3. Triple-Offset Butterfly Valves vs. Gate and Ball Valves: Technical Comparison

 

1) Pressure Rating

Metal-seated butterfly valves typically reach Class 300–600, with some up to Class 900.

Gate and ball valves commonly cover Class 1500, and in some cases up to Class 2500.

Conclusion: Butterfly valves are competitive for pressures up to Class 600; for higher pressure ratings, gate or ball valves are still recommended.

 

2) Temperature Capability

Triple-offset butterfly valves: generally around 425°C, higher depending on sealing materials.

Metal-seated ball valves: 425°C–700°C

Metal-seated gate valves: above 600°C

Conclusion: Butterfly valves are suitable for medium to high temperatures, but extreme high temperatures remain the advantage of gate and ball valves.

 

3) Sealing Performance and Leakage Rate

Triple-offset butterfly valves can achieve zero leakage (ANSI Class VI).

Ball valves can also achieve zero leakage.

Gate valves, generally metal-seated, may allow minor leakage within acceptable limits.

Conclusion: Butterfly valves and ball valves have comparable sealing performance, but butterfly valve sealing stability depends more on operating conditions and machining accuracy.

 

4) Operating Torque and Efficiency

Butterfly valves have lower torque and are easier to automate with actuators.

Ball valves require relatively higher torque.

Gate valves have high torque and longer opening/closing times.

Conclusion: Butterfly valves offer advantages in automation integration.

 

5) Cost and Maintenance

Butterfly valves are lower in cost, easier to maintain, lighter, and simpler to install.

Ball and gate valves are more expensive, heavier, and require more maintenance space.

Conclusion: When conditions allow, butterfly valves provide clear economic advantages.

 

4. Real-World Application Case Studies

 

Case 1: Gas-Fired Power Plant Steam Line (450°C, Class 300)

The original design used gate valves, but limited installation space and maintenance difficulties led to replacing them with triple-offset butterfly valves.

Results:

● Stable operation with no noticeable leakage

● Maintenance costs reduced by 40%

● Opening and closing time shortened to 1/5 of the original

 

Case 2: High-Temperature Oil Transfer in Refining Units (520°C, Class 600)

Initially, butterfly valves were tried due to high temperatures, but the sealing rings deformed under prolonged high-temperature conditions. Ultimately, metal-seated ball valves were installed.

Results:

● Ball valves provided more stable sealing life

● No sticking occurred under frequent operation

 

Case 3: Urban District Heating System (200°C, PN40)

Triple-offset butterfly valves replaced gate valves.

Results:

● Valve weight reduced by 70%

● Cost decreased by 30%

● System has operated smoothly for over 5 years without major failures

 

Conclusion: The feasibility of replacing gate or ball valves with butterfly valves strongly depends on temperature, pressure, fluid properties, and operating frequency.

 

5. Engineering Selection Recommendations (Professional Perspective)

 

Situations Where Butterfly Valves Can Be Considered as Replacements:

● Pressure rating ≤ Class 600 or PN40–PN100

● Temperature ≤ approximately 450°C

● Relatively clean media, with minimal solid particles

● Cost, weight, and installation space are important considerations

● Systems requiring fast opening/closing or automation

 

Situations Where Gate or Ball Valves Are Still Recommended:

● Extreme high temperatures (>500°C)

● Extreme high pressures (Class 900 and above)

● Media containing solids, prone to coking or crystallization

● Frequent operation requiring long-term zero leakage

● Critical safety conditions (hazardous media)

 

Final Principle:

Butterfly valves can replace gate or ball valves, but selection must ensure that operating conditions are controllable and that materials and design are appropriately matched.

 

Q&A – Frequently Asked Questions

 

Q1: Can triple-offset butterfly valves achieve zero leakage?

Yes. High-precision triple-offset metal-seated butterfly valves can achieve zero-leakage performance, but strict control of installation and operating conditions is required.

 

Q2: Can butterfly valves be used for media containing particles or slurries?

Not recommended. Particles can become trapped in the sealing surface, reducing valve lifespan. Knife gate valves or specially designed valves are more suitable for such applications.

 

Q3: Why do butterfly valves tend to fail under high-temperature conditions?

The main reason is deformation of the sealing ring material due to high temperature, especially when the operating temperature exceeds the material’s rated limit, leading to reduced sealing performance.

 

Q4: Under high-pressure cyclic conditions, which has a longer service life: butterfly valves or ball valves?

Ball valves generally have a more stable service life because the ball fits tightly against the seat, offering stronger pressure resistance.

 

Q5: How should I select the appropriate valve?

It is recommended to provide operating parameters (media type, temperature, pressure, actuation method, frequency) to the supplier or engineer for selection evaluation, ensuring safety and reliability.