Valves are often perceived as simple and fairly unnoticeable components. In reality, however, they play a critical role in the functionality and safety of industrial processes.
Many valve-related decisions are still based on assumptions or a “this is how it’s always been done” mindset. These misconceptions can lead to unnecessary costs, production downtime, and, in the worst cases, safety risks.
1. “All valves are the same”
Valves may appear similar on the outside and are often considered general-purpose components that can be used anywhere.
In reality, different valve types serve entirely different purposes. For example, a ball valve is an excellent choice for shut-off applications, whereas flow control requires a different type of valve. Valves designed for tank applications also differ structurally from those intended for pipeline use.
Selecting the wrong valve type can lead to poor performance, premature wear, or leakage.
Example:
A valve is selected based solely on size and connection type. As a result, the flow cannot be properly controlled, or the valve wears out quickly due to being used in the wrong application.
2. “Maintenance isn’t needed until something breaks”
A valve can operate for a long time without visible issues, which can make maintenance seem like an unnecessary cost.
However, valves contain wear parts, such as seals, whose condition deteriorates over time. Preventive maintenance is almost always more cost-effective than repairing a failure after it occurs, as faults can lead to sudden leaks, process disruptions, and unplanned downtime.
Example:
A valve operates normally for years until a seal suddenly fails, causing an unexpected production shutdown.
Read more about valve maintenance.
3. “The cheapest valve is the most cost-effective option”
Procurement decisions are often primarily based on purchase price.
In reality, the total cost of a valve is determined over its entire lifecycle: service life, maintainability, availability of spare parts, and operational reliability all play a key role. A low initial price can therefore mean a shorter lifespan and higher overall costs.
Example:
A lower-cost valve needs to be replaced every few years, whereas a higher-quality, maintainable solution would have lasted significantly longer.
4. “The material of a valve doesn’t matter much”
Materials are not visible externally and are therefore often considered secondary factors. In reality, material selection is one of the most critical factors affecting valve performance. Corrosion, temperature, pressure, and chemical properties all impose specific requirements.
In addition, material traceability and documentation are essential from both quality and responsibility perspectives. Incorrect material selection can lead to premature wear, leakage, or even valve failure.
Example:
A valve is installed in a chemical process without properly evaluating material suitability, resulting in rapid corrosion.
Read more about material selection and quality assurance.
5. “One valve solution fits all applications”
Standard solutions are easy and quick to implement, but in reality, processes and operating conditions vary significantly. One solution does not always meet all requirements, especially in demanding or specialized applications.
Example:
A valve performs “well enough,” but not optimally, resulting in continuous minor disturbances or inefficiencies.
Summary
Valve selection is not a minor technical detail; it is an integral part of the overall process. Common misconceptions in valve selection and use can lead to high costs and risks.
When the following factors are taken into account:
- the correct valve type
- material selection
- maintainability
- lifecycle costs
The result is a solution that performs reliably over the long term.
At Maper, valves are always designed with the application in mind. When needed, solutions can also be customized to meet demanding conditions to ensure reliable performance throughout the entire lifecycle.
Not sure which valve solution fits your process? Get in touch, we’ll help you avoid common mistakes and find a solution that works in practice.
18.5.2026
