Funded by the European Union – NextGenerationEU
Project implementation in progress
Development of the Fasek Valve Torque Measurement (FVTM) Smart System, Project Code: PK.1.1.12.0093
FASEK d.o.o. commenced the implementation of the project "Development of the Fasek Valve Torque Measurement (FVTM) Smart System" on 5 January 2026. The project is being implemented in accordance with the rules of the Call for Proposals for the award of grants "IRI S3 – Increasing the Development of New Products and Services Arising from Research and Development Activities", under the Competitiveness and Cohesion Programme 2021–2027. The Level 1 Intermediate Body is the Ministry of Economy, while the Level 2 Intermediate Body is the Croatian Agency for SMEs, Innovation and Investments (HAMAG-BICRO).
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Project leader: FASEK d.o.o.
Project partner: Faculty of Mechanical Engineering and Naval Architecture, University of Zagreb
Total project value: 1.978.960,97 EUR
EU Co-financing: 1.010.915,96 EUR
Project implementation period: 5.1.2026. - 5.1.2029. (36 months)
Project manager and contact person:
Goran Grgić goran.grgic@fasek.hr,
Krešimir Vučković kresimir.vuckovic@fasek.hr
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Project summary
The objective of the project is to research and develop a smart system for continuous, non-invasive valve torque measurement and predictive maintenance in gas and oil pipeline transmission systems, supported by an integrated digital twin ecosystem. The project aims to shift from reactive and periodic maintenance to maintenance based on real-time data and predictive analytics, thereby reducing downtime, maintenance costs, and the risk of incidents affecting energy infrastructure.
The project is implemented by FASEK d.o.o. in cooperation with the Faculty of Mechanical Engineering and Naval Architecture, University of Zagreb, through the phases of industrial research and experimental development, with the objective of validating the solution and achieving Technology Readiness Level 8 (TRL 8).
Scope of development
- Development of a smart system for valve torque measurement based on microstrain measurements on the actuator housing.
- Development and validation of a mathematical model that correlates measured microstrains with the actual valve torque with the targeted level of accuracy.
- Development of hardware components for continuous data acquisition and IoT communication.
- Development of a software platform and digital twin ecosystem for condition monitoring, analytics, and simulation.
- Development of predictive algorithms and machine learning models for condition assessment and fault prediction, including estimation of the remaining useful life of assets.
- Development and construction of a dedicated Test Rig for accelerated testing and system validation under controlled conditions.
- Prototype testing and demonstration in an operational environment, together with preparation for commercialisation.
Key Activities
- Industrial research to validate the hypothesis that actual valve torque can be accurately determined from actuator housing microstrain measurements.
- Numerical modelling and experimental validation of the strain gauge measurement concept using representative actuator geometries.
- Design and construction of the Test Rig platform for simulating loads, operating cycles, working pressures, and different operating media.
- Development and manufacture of FVTM system prototypes, including sensors, electronics, and communication modules.
- Development of the digital twin and cloud platform for data acquisition, storage, processing, and integration with predictive algorithms.
- Accelerated laboratory testing, model calibration, and verification of measurement repeatability.
- Demonstration of the solution under real operating conditions and preparation of a reference pilot project for market deployment.
Expected project results
- Development and validation of the FVTM system as a complete hardware and software solution for continuous, non-invasive valve torque measurement.
- Development of a digital twin ecosystem for condition monitoring, predictive maintenance, and asset management optimisation.
- Development and commissioning of the Test Rig as research infrastructure for accelerated testing and the future development of next-generation products.
- Technological validation of the solution to TRL 8.
- Increased readiness for intellectual property protection and commercialisation in the global industrial diagnostics market.Business impact and wider contribution
- Reduction of downtime and maintenance costs through the transition to predictive maintenance based on real-time data.
- Improved safety and reliability of energy transmission infrastructure, together with reduced risk of environmental incidents.
- Support for the energy transition by enabling infrastructure monitoring under changing operating conditions and with new operating media, including hydrogen.
- Contribution to the S3 priority areas Digital Products and Platforms, Industry 4.0, and Smart and Clean Energy.
- Transformation of FASEK's business profile from a service-oriented company into a manufacturer of high-technology solutions with its own intellectual property.
- Strengthening export potential through the existing international network of the FASEK Group and a combined business model based on hardware sales and platform subscriptions.
Innovation aspect of the project
The FVTM project introduces a new category of diagnostic system for valves used in energy infrastructure by enabling continuous and non-invasive valve torque measurement on equipment already installed in the field, without disassembly or interruption of operation. The innovative approach is based on measuring microstrains of the actuator housing to determine the actual valve torque and integrating these measurements with a digital twin and predictive analytics. Unlike existing invasive or periodic diagnostic solutions, the FVTM system enables 24/7 condition monitoring, fault prediction, and simulation of operating scenarios, allowing maintenance and asset management to evolve towards predictive, data-driven decision-making.
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