What Are three Common Valve Failures? Industry Trends and Best Practices

Expert remarks on the most popular type of butterfly valves3Butterfly valves play a vital role in flow control within various industries, yet as a mechanical application they can fail. These such Failures are very old and should be taken in consideration when you are dealingwith special series versions as the Cast Iron Lug Butterfly Valve, Double Flanged Butterfly Valve or Stainless Steel Flange Butterfly Valve. Below are three common failure modes that can apply to many different types ofbutterfly valves.

1. Seat Deterioration and Leakage

The seat, which provides the valving component atight seal when closed, is a common source of failure. For example, in the Rubber Lined Pinless Butterfly Valve, or the Soft Seat And Lever Operator grooved end butterfly valve, the soft seat (commonly EPDM,Nitrile, or PTFE) is subject to wear. It can be compromised by high temperatures, chemical attack, abrasive media, or just wearand tear with time. Cavitation/high velocity flow can also wear out the sealsurface. Seat failure results in an internal leak,and the valve will no longer stop fluid flow. In high-end applications, Coating DiscU Section Type Butterfly Valve utilizes special disc coat to increase disc wear and corrosion resistance protection, which directly againstsuch failure mode.

Image: https://ecdn6.globalso.com/upload/p/3478/image_other/2025-08/wechat-image_20250821094811_83-1.png

2. Stem/Bearing Corrosion and Seizure of Stem and Bearing

The stem attaches the disc tothe actuator. "Herefailure often means inoperable valve." In Stainless Steel Flange Butterfly Valves,the stem will be usually stainless to resist corrosion. But in less-expensive versions or inharsh environments, stems and bearings can rust, particularly if seals break down and moisture get inside. A PinleSs Butterfly Valve design removes the through-shaft pin for a potential wear and leak point, the longevityof which is further enhanced. Nonetheless, the stem may seize (beunable to be rotated) due to stem corrosion in general, or accumulation of deposits. Toachieve this jammed state, regular maintenance and proper material selection for the stem and bearings is important.

Image: https://ecdn6.globalso.com/upload/p/3478/image_other/2026-04/electric-flange-butterfly-valve.jpg

3. Actuator and Operational Failure

Butterfly valves depend on an operator - whether that is a simplelever, gearbox, or automated system such as a Pneumatic Butterfly Valve. This system is notoriousfor failures. Many linkages especially from lever operated valves can be bent by over-torquing or disc can be damaged.

Image: https://ecdn6.globalso.com/upload/p/3478/image_other/2026-03/penumatic-lug-butterfly-valve.jpg

Pneumatic Butterfly Valves, air supplyfailure, solenoid valve malfunction, diaphragm leak or spring return mechanism failure will cause valve STOP working. A evenworking valve body will fail if its actuator does. Thisis why it is so important to choose the right size actuator for the valve torque and the type of valve, whether it be Double Flanged Butterfly Valve for high pressure piping or Grooved End for faster installation.

Conclusion

Selecting the best valve designfor the service is the first line of defence in these possible failure. The Cast Iron Lug Butterly Valve is economical in most of water works, whereas Stainless Steel Flange Butterfly Valve is anti-corrosion. Understanding common failures-seat wear, stem seizure, and actuator

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