Reducing the maintenance frequency of valves requires comprehensive measures from multiple aspects such as design optimization, material selection, operating specifications, monitoring technology and preventive maintenance strategies. The following are some specific measures:

1. Optimize valve design and material selection

1-1. Corrosion-resistant and wear-resistant materials:

(1) Select corrosion-resistant materials (such as duplex stainless steel, Hastelloy) or surface treatment (plating, nitriding, sprayed tungsten carbide) to reduce failures caused by corrosion and wear.

(2) In scenarios with particulate media, use hardened balls and valve seats (such as tungsten carbide coating) to resist wear.

1-2. Self-lubricating design:

Use self-lubricating valve seat materials (such as PTFE-filled graphite or PEEK) to reduce friction loss and extend seal life.

1-3. Redundant sealing structure:

Use dual piston effect (DPE) or dual isolation and exhaust (DIB) design to improve reliability and reduce leakage risk through multiple seals.

2. Improve manufacturing and installation quality

2-1. Strict manufacturing standards:

(1) Follow API 6D, ISO 14313 and other standards to ensure the performance of valves under extreme conditions such as high pressure and high temperature.

2-2. Precision installation:

(1) Avoid pipe stress or misalignment during installation to prevent valve deformation or leakage due to uneven force.

(2) Use professional torque tools to tighten bolts to prevent overtightening or loosening.

3. Intelligent monitoring and predictive maintenance

3-1. Condition monitoring technology:

(1) Integrated sensors (such as pressure, temperature, and vibration sensors) monitor valve status in real time and transmit data to the control center through the Internet of Things (IoT).

(2) Use AI algorithms to analyze data, predict seal wear, jamming and other faults, and intervene in advance.

3-2. Leak detection system:

Use ultrasonic or infrared technology to detect small leaks to avoid frequent maintenance due to leak expansion.

4. Standardize operation and operating condition control

4-1. Avoid frequent switching or partial opening:

(1) Reduce the use of valves in throttling state (such as using regulating valves instead) to reduce wear caused by turbulence and cavitation.

(2) Optimize operating procedures to avoid unnecessary start and stop.

4-2. Control the cleanliness of the medium:

Install filters or separators upstream of the valve to remove solid particles, moisture and impurities in natural gas to prevent scratches on the valve seat and ball.

5. Use maintenance-free or long-cycle design

5-1. Metal-sealed valves:

(1) Under high temperature or high pressure difference conditions, use metal-to-metal seals (such as nickel-based alloys) to replace traditional soft seals to extend service life.

5-2. Modular design:

Design valve seats and sealing modules that can be quickly replaced to reduce downtime and maintenance complexity.

6. Optimize environmental adaptability

6-1. Extreme temperature protection:

(1) In low temperature (such as LNG) applications, use cryogenically treated materials (such as 316L stainless steel) and vacuum jacket insulation design to prevent material embrittlement.

(2) In high temperature scenarios, use heat sinks or thermal insulation coatings to reduce the impact of thermal stress.

6-2. Explosion-proof and fire-proof design:

Comply with API 607 fire protection standards and use graphite fire-proof seals to ensure that the valve can still be reliably closed in the event of a fire, reducing the need for maintenance after an accident.