Bolted Flange Connection Leakage: A Systematic Review of Monitoring Challenges and Technologies

Ensuring leak tightness and preventing emissions in bolted flange connections (BFCs) are critical for maintaining safety, reliability, and environmental compliance in industrial systems. This article offers a comprehensive review of techniques to improve installation processes and establish effective monitoring systems for BFCss. The discussion on installation techniques focuses on achieving the appropriate gasket surface pressure to minimize leakage risks and enhance long-term reliability. The importance of proactive monitoring during installation is emphasized, as it enables the early detection and resolution of potential issues. The review also explores long-term monitoring strategies, spanning both traditional methods and advanced technologies. While direct observation is cost-effective, it lacks precision and fails to ensure safety. More advanced approaches, such as internal mass balance and real-time transient models, deliver superior detection and quantification capabilities, albeit with increased complexity and cost. External monitoring systems, such as cable-based sensors and hydrocarbon-sensing tubes, are highlighted for their effectiveness in broad-scale applications. Meanwhile, advanced techniques such as bolt load monitoring and fiber-optic sensing offer state-of-the-art solutions for identifying leaks and emissions. This article organizes these methodologies into distinct categories and provides a practical framework for applying them across various operational contexts. By emphasizing advancements in real-time monitoring and leak prevention, this article promotes safer and more sustainable industrial practices, laying the foundation for future innovations in bolted flange sealing technology.