Purchasing low-cost valves can be tempting, especially on a project with tight budget constraints. While this saves dollars in the short run, plant personnel may be faced with costly issues once the plant is operating – shorter valve life cycles, leakage, forced shutdowns, repairs, replacements and, in the worst case, accidents. While it may carry a higher up-front cost, investing in the right quality valve solutions reduces direct maintenance costs and lost production due to downtime, ultimately providing a better return on investment over the service life of the valve.
Increased emphasis on ESG and sustainability reporting will require businesses to adjust their thinking about cost to include the social and environmental impacts of procurement choices from “cradle to grave” or, in a more circular way, from “cradle to cradle” when reuse or recycling are possible. Reducing waste and lowering safety and environmental risks deliver additional value add beyond up-front cost savings when ESG impacts are considered in procurement.
Our goal at Armour Valve is to help our customers select solutions that will deliver the best overall long-term value. We are often called on to help replace “problem valves” that wear out in service much more quickly than anticipated. Our customers are surprised at the full cost of inferior valves selected primarily on price or because they meet minimum specification requirements.
Below is an oversimplified example of TCO for valves that have a significant difference in purchase price to help illustrate this point. The higher quality valve can be repaired in-line at lower cost and with longer time between maintenance. Without accounting for the full TCO that would include additional acquisition costs, disposal costs, and lost production, the high-quality valve that requires less frequent maintenance is the clear winner. The $9,700 saved up front by purchasing the low-cost model is negated in the first 3 years due to maintenance.
Cost Category Low-Cost Option High-Quality Option Purchase price $16,000 $25,300 Installation cost $7,000 $7,000 Maintenance cost per cycle $7,000 $3,000 Maintenance cycle (years) 1 3 Expected lifespan (years) 3 15 Total maintenance 10 4 Total replacements 5 1Total Maintenance Cost $70,000 $12,000 Total Replacement Cost $51,000 $28,300 $121,000 $40,300
Although lowest total cost of ownership can be achieved on your own, working with a reputable supplier can help you save time sourcing a solution. It also allows you to work with industry experts to help you find the best-fit solution for your specific application and support you long after your initial purchase.
When researching a valve supplier, we recommend that you confirm up front how they approach maintenance, whether they stock or can provide replacement parts in a timely manner, and the expected cost and frequency of replacement in the application. These are crucial factors when determining your total cost of ownership.
Conval manufactures valves for the world’s most demanding service that can be repaired in-line, saving time and money and reducing waste and downtime. The modular design ensures that parts that are manufactured today are compatible with valves that have been in service for years. We know of Conval valves that have been performing in service for decades.
Boehmer District Energy ball valves offers durability ensuring several years of corrosion free performance. A fully welded trunnion mounted design ensures there are no leak paths and that the valve is able to operate and fully seal even after several years in service. It is designed to be maintenance free under normal operating conditions, making it especially attractive for buried service where they can perform in service 30+ years.
VRG Valve Pilot Controllers are easily adaptable to most control valves. The modular plug and play design allows for five (5) Valve Pilot Controllers in a single platform providing flexibility in converting from one model to another with ease. Not only does this make maintenance easier; it is also less costly as fewer repair kits are needed.
Quality engineered solutions and the correct selection of valves for the application are needed to ensure optimal process performance. With 50+ years of experience in energy and industrial applications and a team of knowledgeable valve professionals, Armour Valve is equipped to help you identify solutions that will deliver value to your plant over a long service life. Contact Armour Valve to set up a one-on-one consultation with our team.
Frequent clogs. Wasted material. Time lost on cleaning and repairs. And literal holes pitted throughout the structure of your rotary valve.
That’s what you get when you buy the cheapest possible valve. Not to scare you or anything, but a cheap valve can cost you more money and hassle in the long run. The right valve, on the other hand, actually saves money and makes your job easier.
Does ACS Valves make cheap valves or expensive ones? Well, the honest answer is neither. It’s not fall-apart-in-your-hands cheap, and it doesn’t come studded with diamonds and a serving of caviar. The actual price depends on what makes the most sense for your conveying system.
Our goal is to give you the best possible value every time you order from us. What does that actually mean? You’re asking all the right questions.
When valves are fabricated outside of North America, the quality can be a little… unreliable. Oftentimes that makes the machine itself looks rough and porous, like it wasn’t cast properly. With a valve like this, you might notice pitting, air holes or increased clearances where air can leak through.
This is especially bad if you’re conveying an abrasive product, because improper clearances create a kind of cyclone that sandblasts the holes and makes them worse as the rotor blades turn. That’s a big no-no in sanitary applications, because bacteria can proliferate in holes and pitted areas.
Considering it’s meant to be, you know, an airlock, your valve should only have two holes: one at the inlet and one at the outlet.
“Quality makes a huge difference. That’s why the entire manufacturing team at ACS is qualified or certified in some manner,” explains Megan Thompson, President and COO of ACS Valves. “There are inspections at pretty much every step in the process of assembling a valve. We make sure it has the proper clearances and high-quality machining and welding from top to bottom.”
She adds that ACS Valves does not outsource anything but the castings, which are also done in North America. “Everything is built in-house, so we control the quality.”
When it comes to rotary valves, a big part of the value lies in customization. Here’s the deal: if a standard valve fits, it fits. There’s no need to upsell you. But often our customers have specific applications, materials and machinery that require a more tailored solution.
“If you just put a standard valve in an application that requires more options, it will wear out faster,” Thompson explains. Let’s say it’s an application with abrasive, coarse or corrosive material — in cases like those, you need coatings that protect your valve from premature wear.
In other cases, it could be an accessory that breaks up chunky material, a rotor that fine-tunes the flow of material, or even a unique valve that lets you clean food buildup in minutes instead of hours. Whatever the case, ACS experts know conveying systems well enough to recommend what works best.
Wait, so how does that save you money? Here are some common scenarios:
Customization is one major aspect of our service at ACS Valves, but there’s more to it.
“If a customer calls, we want to gather all the details of their application and pick the right valves, options and sizing,” says Thompson. “We don’t treat our customers like part numbers.”
In other words, we care. We will take the time to make sure everything is just right at every step, from the initial discussion to the final shipment. (By the way, if you’re curious about our ordering process, we have a handy little video for you here.)
Plus, our service doesn’t stop after you receive the valve. We provide consulting and aftermarket support to help you get the valve installed properly and walk you through any potential issues. If you ever have questions, we’re just a phone call away.
We’re almost sorry that we have to point this out, but many of our competitors charge extra for NFPA compliance. We don’t. The standard configuration for our 6”–16’’ CI, MD and DR-S Series valves is fully compliant with NFPA standards. That’s not possible with every valve, but we’re upfront about your options and always happy to recommend more ways to improve your plant’s safety.
With all that in mind, we understand you might still have some questions about our rotary airlock valves, how they’re manufactured and how they benefit you. Contact a friendly rep to talk it out.
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