Leakage Detection & Gasket Condition Monitoring Platform
Remote leakage detection for safety-critical industrial systems
2M Engineering develops OEM-ready sensor platforms for leakage detection and gasket condition monitoring in safety-critical and hard-to-reach industrial environments. These solutions enable continuous, remote insight into sealing integrity in pipelines and pressurised systems—without the need for physical inspection.
A proven implementation of this platform approach is the Smart Gasket Sensor, an intelligent, photonics-based gasket system developed by 2M Engineering in collaboration with industrial partners. It demonstrates how advanced fiber-optic sensing, mechanical design, and industrialisation can be combined into a scalable OEM solution for predictive maintenance and risk reduction.
From periodic inspection to continuous sealing integrity monitoring
The challenge
Pipelines transporting gas, oil, water, or chemicals rely heavily on gasketed flange connections. Leakage typically occurs at these interfaces and often remains undetected until failure becomes visible or dangerous.
Traditional preventive maintenance relies on:
- Periodic torque checks
- Manual inspection by specialists
- Ultrasonic or acoustic testing
- Physical presence in hazardous or inaccessible locations
This approach is costly, reactive, and often too late—especially in offshore, nuclear, chemical, or hygienic environments.
The platform solution: Smart Gasket sensing
2M Engineering developed a fiber-optic gasket monitoring platform that continuously measures mechanical deformation, pressure, and temperature inside a gasket during operation.
Using Fiber Bragg Grating (FBG) sensing technology, small deformations in the gasket are translated into accurate optical signals. These signals provide real-time insight into gasket condition, enabling early detection of:
- Loss of sealing force
- Thermal or pressure-induced degradation
- Progressive leakage risks
The result is true condition-based maintenance, without physical intervention.
Key platform characteristics
- Continuous, real-time gasket condition monitoring
- Fiber-optic sensing (intrinsically safe, EMI-immune)
- Suitable for explosive and hazardous environments
- No electrical components at the sensing location
- Remote monitoring—no on-site specialists required
- Designed for predictive maintenance strategies
Designed for extreme and safety-critical environments
This platform is specifically suited for environments where access is limited, risks are high, or hygiene is critical:
- Petrochemical and chemical plants
- Nuclear power facilities
- Offshore and subsea installations
- Aggressive or hazardous fluids and gases
- Food and pharmaceutical processing
The sensing principle is non-electrical at the point of measurement, making it inherently safe for explosive zones.
Preventive vs condition-based maintenance
Traditional preventive maintenance
- Requires physical presence
- Periodic torque checks
- Manual inspections
- Downtime and safety exposure
Smart Gasket platform
- Continuous monitoring
- Remote data acquisition
- Early warning before leakage
- No regular physical intervention
This shift significantly reduces:
- Maintenance labour
- Unplanned downtime
- Environmental incidents
- Liability and compliance risks
Engineering challenge: sensing under extreme loads
A key innovation of the Smart Gasket platform is the ability to convert large mechanical forces and deformationswithin a gasket into microscopic, measurable strain that remains within the operating limits of optical fibers.
Key challenges addressed:
- Extreme pressure and compressive forces
- High operating temperatures
- Long-term material stability
- Mechanical-optical integration
- Manufacturability at scale
This required close integration of mechanical design, materials engineering, photonics, and system integration.
Proven reference implementation: Smart Gasket Sensor
The Smart Gasket Sensor is a validated implementation of this platform and is currently deployed with a world-leading gasket manufacturer.
Platform highlights
- Fiber Bragg Grating (FBG) sensing
- Pressure and temperature monitoring
- Continuous sealing integrity assessment
- Suitable for hard-to-reach and hazardous locations
- Remote data transmission to monitoring systems
OEM platform approach
2M Engineering supports OEM partners with:
- Sensor concept and feasibility studies
- Mechanical and photonic integration
- Industrial design for harsh environments
- Industrialisation and manufacturability
- Transfer to OEM production where required
The Smart Gasket Sensor demonstrates how complex sensing challenges can be transformed into robust, scalable OEM platforms.
Partners & ecosystem
- 2M Engineering – system architecture, sensor development, industrialisation
- FOCE – fiber-optic communication technology
- KeyTec Netherlands B.V. – manufacturing partner
This project was supported by the European Regional Development Fund (EFRO / OP-Zuid).
Interested in leakage detection for your application?
The Smart Gasket Sensor is one example of how 2M Engineering enables next-generation leakage detection and condition monitoring platforms. We collaborate with OEMs to develop custom solutions tailored to specific fluids, pressures, environments, and regulatory constraints.
→ Contact 2M Engineering to explore OEM leakage detection solutions
This project is made possible by a contribution from the European Regional Development Fund as part of OP-Zuid. Hier wordt geïnvesteerd in uw toekomst! For more information see EFRO.
