HOT BOLTING PROCEDURE

Introduction

 Hot bolting is the one at a time removal,

cleaning, lubricating and replacement of
nuts and bolts from flanges of process
plant in service
 Objectives
 To outline the factors in an engineering
assessment to determine if hot bolting is
acceptable
 To set out the assessment and approval
process before hot bolting commences
 To define the steps involved in the actual
hot bolting process
 Responsibilities

Engineering Assessor

responsible for establishing if the

equipment, plant operating conditions and
general circumstances are suitable to
allow hot bolting
 Responsibilities Cont…..
Area Authority
responsible for :-
 preparing and completing the hot bolting
certificate and through a permit to work
 giving his approval for work to proceed
If competent
 he may also act as the Engineering Assessor
 He also ensures the work has been properly
completed and the hot bolting certificate signed
off
 Responsibilities Cont…..

Performing Authority

responsible for undertaking the work in

accordance with this Procedure and the
controls spelt out in the engineering
assessment and permit to work
Initial Engineering Assessment

An initial engineering assessment must be

made by a qualified person to establish
that the proposed hot bolting can
proceed safely.
Initial Engineering Assessment
Cont….

 The following factors are considered:-

 Plant contents
 Mechanical considerations
 Operating pressures
 Vibration
 Temperature
 Access conditions
 Maintenance and leak history
 Condition of joints and bolts
 Pipe support condition
Initial Engineering Assessment
Cont….

 Plant contents :- limitations will be

applied to plant containing toxic
materials

 Operating pressures:- actual operating

pressure during hot bolting must be
within the limits and must be able to be
maintained stable within those limits
 Hot Bolting Table of Limitations

 Maximum Temperature 90C in all cases

 Not allowable in flanges having less than 8 bolts
 Not allowable any hot cutting of bolts
Max Allowable Line Operating
Service and Line Specification
Pressure During Hot Bolting (psi)
Crude Oil

PSI 170 CL150

PSI 450 CL300
PSI 900 CL600
PSI 900 CL 900
PSI 900 CL 1500
PSI 900 CL 2500
 Hot Bolting Table of Limitations Cont ….

Max Allowable Line Operating Pressure During

Service and Line Specification
Hot Bolting (psi)

Gas and NGLs

170 PSI CL 150

450 PSI CL 300

450 PSI CL 600

450 PSI CL 900

450 PSI CI 1500

450 PSI CL 2500

 Hot Bolting Table of Limitations Cont ….

Max Allowable Line Operating Pressure During

Service and Line Specification
Hot Bolting (psi)

Utilities (Air / Diesel / Fire water)

170 PSI Cl 150

450 PSI Cl 300

900 PSI Cl 600

1350 PSI Cl 900

2250 PSI Cl 1500

Initial Engineering Assessment
Cont….

 Temperature :- must be less than 90C

 Mechanical considerations:-
 Number of bolts – minimum 8
 Standard bolts (B7/2H)
 Standards flanges (ANSI B16.5)
 Standard gaskets used
 No expansion bellows
 Pipe support location suitable
 Preparatory Work
 For every flange to be hot bolted, if the
assessment indicates that hot bolting may
be acceptable, a hot bolting certificate will
be prepared and endorsed by the
department supervisor/Area Authority
 Preparatory Work Cont…
 In completing the permit the Area Authority must
consider:-
 Access – easy access and escape in case a leak should start should
be provided

 Safety Equipment – includes PPE in case of leakage and fire, fire

watch etc.

 Instruction – personnel to be advised of the risks, the procedure if a

leak should arise and the need to keep the flange under observation
at all times a bolt is not in place

 Contingency Plan – how to isolate the flange if a leak should occur,

communications arrangements, emergency response
 Hot Bolting Work Method

1. The Area or Performing Authority will first

check all bolts are properly tightened. Any
abnormalities :
loose, seized, stripped
will be reported and the task reassessed.
 Hot Bolting Work Method Cont …

2. Bolts will then be removed one at a time

in the sequence specified Later, Bolts
should only be removed using HAND
TOOLS .
Flogging spanners
and
air wrenches
should not be used.
 Sequence of Bolt Removal and
Replacement During Hot Bolting

The first bolt (Number 1) to be removed

should be selected. All other bolts are then
numbered sequentially from number 1 in a
clockwise direction using a suitable
marker pen
 Sequence of Bolt Removal and
Replacement During Hot Bolting Cont…

 8 Bolt Flange
Removal and Replacement Sequence:-
1-5-3-7-4-8-2-6
 12 Bolt Flange
Removal and Replacement Sequence:-
1-7-4-10-2-8-5-11-3-9-6-12
 Sequence of Bolt Removal and
Replacement During Hot Bolting Cont…
 16 Bolt Flange
Removal and Replacement Sequence:-
1-9-5-13-3-11-7-15-2-10-6-14-4-12-8-16
 20 Bolt Flange

Removal and Replacement Sequence:-

1-11-6-16-3-13-8-18-4-14-9-19-5-15-10-20-
7-17-2-12
 Sequence of Bolt Removal and
Replacement During Hot Bolting Cont…

 24 Bolt Flange
Removal and Replacement Sequence:-
1-13-7-19-10-22-4-16-12-24-6-18-14-2-8-
20-11-23-5-17-9-21-3-15
 Hot Bolting Work Method Cont …

3. The bolts will then be cleaned and

lubricated, and then replaced and correctly
tightened up .

Damaged or corroded bolts

will be renewed.
 Hot Bolting Work Method Cont …

4. After all bolts have been removed and

replaced, a final check on their tightness
will be made before the hot bolting
certificate is signed off
by the Area Authority.
 HOT BOLTING CERTIFICATE

PRIMARY ASSESSMENT 9 from P&Ids/Maint. History/Current .1

).…Operations etc
Line / Vessel contents .Line / Vessel No
Normal Operating temp.(ºC/ºf) Normal Operating pressure
(barg/psi)
Flange Standard / Rating Joint Location(s)
Piping Specification Gasket Type / Specification
Location Sketch attached (yes/no) Number of Joints to be Hot
Bolted
Grade of Bolt Number of Bolts in Flange
Torque Setting Bolt Diameter
 HOT BOLTING CERTIFICATE cont…
secondary assessment ( Site Inspection) .2
No Yes No Yes

Flange/Gasket type is Number of bolts is 8 or

as specified more
Pipe supports Bolt material as specified in
inspection design
satisfactory
Adequate Access Joint inspected satisfactory
Previous Experience Joint is free from
with joint or similar Significant vibration
 HOT BOLTING CERTIFICATE
cont…

LINE OPERATING CONDITIONS TO BE MAINTAINED DURING .3

HOT BOLTING
Max. / Min. Pressure ( barg/psi) Line/Vessel /Fluid

Max. / Min. Temperature (ºC/ºf)

Notes. 1. Max. pressure must not exceed values listed in the previous
Hot Bolting table of Limitations
Fluid Temperature must not exceed 90ºC. (Personnel .2
.)Protective Clothing above 60º
 HOT BOLTING CERTIFICATE
cont…

PRESPARATIONS .4
No Yes No Yes

Bolt Removal Bolt Removal sequence

Methods Issued Issued

Contingency Plan Provision for Cold Bolt

Prepared Cutting

Equipment / Materials Bolt Tightening procedure

Available issued

Notes. Hot Cutting is Not Allowed

 HOT BOLTING CERTIFICATE
cont…

5. THE ASSESSMENTS AND PREPARATIONS ARE COMPLETE

Signed……………………… Date……………………
Engineering Assessor

APPROVAL TO PROCESS in accordance with procedures specified .6

YES NO

7. FINAL INSPECTION / MECHANICAL COMPLETION :

The Joint (s) has/have been inspected and Hot Bolting is confirmed as mechanically

complete

Signed…………………… Date…………………
Area Authority

8. ANY OTHER COMMENTS OR ADDITIONAL DATA SHOULD BE ATTACHED TO THE

CERTIFICATE