Mechanical Clamp Design

Simplified method

Baher Elsheikh
April 2022
Rev_01 1

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, L
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
𝑡 = 𝑑 𝐶𝑃/𝑆𝑓𝐸 …… Eq.2 .
• Line size, OD
• Clamp Inside diam., ID
P: Clamp design pressure = max of line design pressure Pd and sealant injection pressure Pi
• Clamp Length, Lt
Pi can be assumed 1.1 X Po • Pipe material
C: Unstayed head factor= 0.33 • Clamp material
• Clamp material allowable stress at Td, Sf
Sf: Clamp material allowable stress at Td, ASME sec. II part D
• Service media
d: Clamp shell internal diameter • Corrosion Allowance, CA
• Number of bolts, n
• Bolt size, D
• Bolt material
End Plate • 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
𝑴 σ𝒎𝒂𝒙 𝐼𝑥 =
M: Bending moment , σmax: Maximum stress@ ymax 12
=
𝑰 𝒚𝒎𝒂𝒙
𝑳𝒕𝑻𝟐
M= 𝛔𝒎𝒂𝒙 𝑻= 𝟔 𝑴/𝑳𝒕σ𝒎𝒂𝒙 𝑻 = 𝟐. 𝟒𝟓 𝑴/𝑳𝒕σ𝒎𝒂𝒙
𝟔
Circular Flange (code appendix Y case) Non-Circular Flange

L = length at the lug (both sides)

L = circumferential length at the B.C.D excluding
L= (Lt – nD) x 2 n: no. of bolts, D: bolt hole .. For symmetrical pipe clamp
the bolt holes
*for special shapes, L to be equal to overall length of the lug all sides
L= 𝜋C-nD C:B.C.D , n:no. of bolts, D: bolt hole 𝛔𝒎𝒂𝒙 : allowable stress
𝛔𝒎𝒂𝒙 : allowable stress
1

𝑴 𝑴
𝑴 …… Eq.3 𝑻 = 𝟐. 𝟒𝟓 General Form 𝑻 = 𝟐. 𝟒𝟓 …… Eq.4
𝑻 = 𝟐. 𝟒𝟓 𝟐 𝑳𝒕 − 𝒏𝑫 𝑺𝒇 𝑳 − 𝒏𝑫 𝑺𝒇
𝜋𝑪 − 𝒏𝑫 𝑺𝒇 . .
L: overall length of lug all around

Mechanical Clamp Design Baher Elsheikh

 Classification: General Business Use
Min Required Bolt Loads
Hydrostatic Force acting area A = ID X L
Examples how to Calculate L and n
1
P= max of line design pressure Pd and sealant injection pressure Pi
L1
Required Bolt load Wm shall be not less than F + factor of safety (FS) … (FS can be
L2
taken 10%)
Lt

L3
Allowable bolt load Wma= Ab X Sb X n
L5
L4
Lt
L = 2Lt & n= 6 L = L1+ L2 +L3+L4+L5
n = 16 “M", Applied moment to be substituted in Eq.3 and Eq.4
M = F X Moment arm

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

Mechanical Clamp Design Baher Elsheikh

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

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, T

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 leal 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

Thank You
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