Processes, Vol. 14, Pages 72: Analysis of Sealing Characteristics of Hydraulic Clamping Flange Connection Mechanism

Processes doi: 10.3390/pr14010072

Authors:
Xiaofeng Liu
Qingchao Bu
Sitong Luan
Xuelian Cao
Yu Zhang
Chaoyi Mu
Junzhe Lin
Yafei Shi

A novel hydraulically actuated uniform clamping flange connection mechanism is proposed to address the long-standing challenges in high-pressure natural gas flowmeter calibration, including cumbersome bolt-by-bolt assembly/disassembly, high leakage risk, and severe non-uniform gasket contact pressure associated with conventional multi-bolt flanges. Unlike traditional discrete bolt loading, the proposed mechanism generates a continuous and actively adjustable circumferential clamping force via an integrated hydraulic annular piston, ensuring excellent sealing uniformity and rapid installation within minutes. A high-fidelity transient finite element model of the hydraulic clamping flange assembly is established, incorporating the nonlinear compression/rebound behavior of flexible graphite–stainless steel spiral-wound gaskets and one-way fluid–structure interaction under water hammer loading. Parametric studies reveal that reducing the effective clamping area to below 80% of the original design significantly intensifies stress concentration and compromises sealing integrity, while clamping force below 80% or above 120% of the nominal value leads to leakage or component overstress, respectively. Under steady 10 MPa pressurization, the flange exhibits a maximum stress of 150.57 MPa, a minimum gasket contact stress exceeding 30 MPa, and a rotation angle below 1°, demonstrating robust sealing performance. During a severe water hammer event induced by rapid valve closure, the peak flange stress remains acceptable at 140.41 MPa, while the minimum gasket contact stress stays above the critical sealing threshold (38.051 MPa). However, repeated water hammer cycles increase the risk of long-term gasket fatigue. This study introduces, for the first time, a hydraulic uniform-clamping flange solution that dramatically improves sealing reliability, installation efficiency, and operational safety in high-pressure flowmeter calibration and similar temporary high-integrity piping connections, providing crucial technical guidance for field applications.

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