Mechanical Clamp Design

Simplified method

Baher Elsheikh
April 2022

Photos from: tdsengineering.com Baher Elsheikh

 Classification: General Business Use
Overview of Mechanical Clamp Design
• A mechanical clamp consists of split fittings mechanically joined together to seal off or reinforce a component
• The annular space between the mechanical clamp and the repaired component can be left either empty or filled, or lined with
epoxy, sealant, fibre, refractory materials, or other compounds.
• A clamp can be non-structural (designed to contain leaks) or structural (designed to reinforce and hold together a damaged
component).

Design of the mechanical clamp involves

1- Main Shell Thickness

4
2- End Flat Plate Thickness
1
3- Lug Thickness
4- Number and size of bolts 2

Assumptions
• Non structural clamp
• Non gasketed (metal-to-metal) 3
• Sealant injection will be applied
• Stable uniform operating conditions

Mechanical Clamp Design Baher Elsheikh

 Classification: General Business Use

Main Shell Thickness Input Data

• Line Design Pressure, Pd
Apply ASME BPVC sec. VIII div.1 UG-27 – EQ.1 • Line Design Temperature, Td
• Line Operating Pressure, Po
• Line Operating Temperature, To

PR • Clamp design pressure, P

t= .
+ CA …… Eq.1 .
SfE – 0.6 P • Line size, OD

Main Shell • Clamp Inside diam., ID

P: Clamp design pressure = max of line design pressure Pd • Clamp Length, Lt
and sealant injection pressure Pi
• Pipe material
Pi can be assumed 1.1 X Po • Clamp material
• Clamp material allowable stress at Td, S
Sf: Clamp material allowable stress at Td, ASME sec. II part D
• Service media
• Corrosion Allowance, CA
R: Clamp shell internal radius
• Number of bolts, n
• Bolt size, db
• Bolt material
• Bolt material allowable stress, Sb

Mechanical Clamp Design Baher Elsheikh

 Classification: General Business Use

End Flat Plate Thickness Input Data

• Line Design Pressure, Pd
Apply ASME BPVC sec. VIII div.1 UG-34 – EQ.1 • Line Design Temperature, Td
• Line Operating Pressure, Po
• Line Operating Temperature, To
• Line size, OD
𝑡 = 𝑑 𝐶𝑃/𝑆𝑓𝐸 …… Eq.2 .
• Clamp Inside diam., ID
• Clamp Length, Lt
C: Unstayed head factor= 0.33 • Pipe material
• Clamp material
Sf: Clamp material allowable stress at Td, ASME sec. II part D
• Clamp material allowable stress at Td, Sf
d: Clamp shell internal diameter • Service media
• Corrosion Allowance, CA
• Number of bolts, n
• Bolt size, D
End Plate • Bolt material
• Bolt material allowable stress, Sb

Mechanical Clamp Design Baher Elsheikh

 Classification: General Business Use
Lug Thickness
Apply ASME BPVC sec. VIII div.1 appendix Y – Eq Y-9 …… Eq.3 .

Derivation
Lug
𝑰 𝐿𝑡 𝑇3
𝒁= Z: section modulus , I: Area moment of inertia , ymax= T/2 𝐼= T
𝒚𝒎𝒂𝒙 12
𝑳𝒕 𝑻𝟑/𝟏𝟐 𝑳𝒕 𝑻𝟐
𝒁= 𝒁=
𝑻/𝟐 𝟔 Lt
𝑎3𝑏
𝐼𝑥 =
𝑴 σ𝒎𝒂𝒙 12
= M: Bending moment , σmax: Maximum stress@ ymax
𝑰 𝒚𝒎𝒂𝒙
𝑳𝒕𝑻𝟐
M= 𝛔𝒎𝒂𝒙 𝑻= 𝟔 𝑴/𝑳𝒕σ𝒎𝒂𝒙 𝑻 = 𝟐. 𝟒𝟓 𝑴/𝑳𝒕σ𝒎𝒂𝒙
𝟔

Non-Circular Flange
Circular Flange (code Appendix Y case)
L = length at the lug (both sides) excluding the
L = circumferential length at the B.C.D excluding bolt holes
the bolt holes
L= (Lt – nD) x 2 n: no. of bolts, D: bolt hole
L= 𝜋C-nD C:B.C.D , n:no. of bolts, D: bolt hole *for special shapes, L to be equal to overall
length of the lug
𝛔𝒎𝒂𝒙 : allowable stress
𝛔𝒎𝒂𝒙 : allowable stress
𝑴 𝑴
𝑻 = 𝟐. 𝟒𝟓 …… Eq.3 . 𝑻 = 𝟐. 𝟒𝟓 …… Eq.4 .
𝜋𝑪 − 𝒏𝑫 𝑺𝒇 𝟐 𝑳𝒕 − 𝒏𝑫 𝑺𝒇
Mechanical Clamp Design Baher Elsheikh
 Classification: General Business Use
Min Required Bolt Loads
Hydrostatic Force acting area A = ID X L

Hydrostatic Force F = A x P

P= max of line design pressure Pd and sealant injection pressure Pi

Required Bolt load Wm shall be not less than F + factor of safety (FS) … (FS can be taken 10%)

Allowable bolt load Wma= Ab X Sb X n

“M", Applied moment to be substituted in Eq.3 and Eq.4

M = F X Moment arm

Use ASME BPVC sec. VIII div.1 appendix 2-6 for reference
n: No. of Bolts hd for loose type flange = (C-B) / 2 [B Flange ID and C: BCD]
ID: Clamp internal diameter
L: clamp length Moment arm = (C – ID) / 2
Pi: Sealant injection pressure pressure
Pd: Line design pressure
𝑪 − 𝑰𝑫
Eq. 4 can presented as 𝑻 = 𝟐. 𝟒𝟓 …… Eq.5 .
Ab: bolt Root area (use ASME PCC 1 – Table H-1M) 𝟐 𝑳𝒕 − 𝒏𝑫 𝑺𝒇
Wm:min required bolt load
Wma: Available bolt load for selected bolt size and numbers

Mechanical Clamp Design Baher Elsheikh

 Classification: General Business Use
Select Clamp Material, Bolt
material and get allowable
stresses at both ambient
and design temperature
from Sec. II part D
Simplified Design Flowchart
Determine the sealant injection Calculate thickness of clamp main
Estimate Clamp pressure (Pi), shell use ASME Sec. VIII div.1 UG-
dimensions, bolt size 27
[approx.: Pi=1.1X Operating pressure]
and numbers (Use max. of Pd and Pi)

Calculate end plate thk, t

use ASME Sec. VIII div.1 UG-34
Start
Calculate total Hydrostatic Force,
F

Calculate required bolt load

Wm=F X FS

No Is required bolt Calculate available bolt load and

load < Available
Increase Bolt Size / number compare to F
bolt load

Yes
Calculate the Lug thickness

Clamp Design
Accepted

Mechanical Clamp Design Baher Elsheikh

 Classification: General Business Use

General Notes
• Use clamp material matching the line material
• Check the line under the effect of external pressure applied by the sealant injection
• Check the actual dimensions at site before fabrication
• MSDS for the sealant component shall be checked and to confirm the adequacy to the operating media and service
• Use corrosion allowance in the design similar to the protected line
• Check the line supports if further adjustment or supports might be required for the weight of the clamp
• Check the actual thickness of the leak line before applying the clamp to identify the required dimensions
• In case the leak is resulted from crack, special cautions and consideration is mandatory be fore applying a clamp, ASME
PCC 2 - Article 306 for guidance
• At high temperature application, B7 bolts will have very low allowable stress and B16 or B8 bolts will be required
• The maximum permissible bolt stress (Sbmax) must be selected to eliminate damage to the bolt or assembly flange. It is
typically in the range of 40% to 70% of ambient bolt yield stress
• The minimum permissible bolt stress (Sbmin) must be selected to provide a lower limit such that bolting inaccuracies do not
become a significant portion of the specified assembly bolt stress, Sbsel. The value is typically in the range of 140 MPa to
245 MPa (20 ksi to 35 ksi)
• For more complex clamp or structural clamp FEA might be applied for accurate results
Note Low strength bolts limitation
Sy for B7 Bolts : 720 Mpa ……….. (140 Mpa= 20%)
Sy fro B8 Cl.1 Bolts: 205 Mpa ……. (140 Mpa= 68%)
Mechanical Clamp Design Baher Elsheikh
 Classification: General Business Use
References and Recommended Readings

ASME BPVC Sec VIII Div.1; –Appendix 2 & Appendix Y

ASME PCC1 –2019; Guidelines for Pressure Boundary Bolted Flange Joint Assembly

ASME PCC2 –2018; Repair of Pressure Equipment and Piping

Introduction to the design and behavior of Bolted Joints , John H. Bickford

Mechanical Clamp Design Baher Elsheikh

Classification: General Business Use

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