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North Sea SPU (UK)

Hot and Odd Bolting Procedure

Issuing Document Stuart Brooks

Authority: Authority: Mechanical Engineer
Document Janet Ross Applicability: North Sea SPU (UK)
Administrator: OMS Advisor
Issuing Engineering Control Tier: 2
Department:
First Issue Date: August 2001 Revision No: Issue 3/AM02
Revision Date: November 2010 Review Required By: July 2013
Revision Summary: Correction of typographical error in Hot/Odd Bolting Certificate.
For further information contact DCC at ODL on 01224 628018 or dcc@odl.co.uk.
Document Location: Documentum/ABZ Federal/SMS

UKCS-SOP-027
 Hot and Odd Bolting Procedure UKCS-SOP-027

Contents

Paragraph Page

1 Terminology 3

2 Purpose 3

3 Scope 4
3.1 Standard Requirements 4
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3.2 Specific Exclusions 4

3.3 Approval for Exceptional Hot or Odd Bolting 4

4 Application 5
4.1 General 5
4.2 Potential Hazards 5

5 Responsibilities 6
5.1 Area Engineering Services Team Leaders (AESTLs) 6
5.2 OIMs/Site Managers 6
5.3 Area Authorities 6
5.4 Performing Authorities 8
5.5 Mechanical Responsible Persons 8
5.6 Multi-skilled Team 8

6 Planning 8
6.1 Introduction 8
6.2 Completion of Hot/Odd Bolting Certificate 9
6.3 Preparations 10

7 Procedures 12
7.1 Hot Bolting Procedure 12
7.2 Odd Bolting Procedure 14

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 UKCS-SOP-027 Hot and Odd Bolting Procedure

Contents

Table Page
1 Factors to be Assessed 9

Figure
1 Hot and Odd Bolting Procedure Flowchart 1
2 Hot/Odd Bolting Certificate 7
3 Hot Bolting Removal and Tightening Sequence 13
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4 Odd Bolting Bolt Removal and Tightening Sequence 15

Addendum 1 Terms of Reference and Monitoring Protocol

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 Hot and Odd Bolting Procedure UKCS-SOP-027
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Figure 1 Hot and Odd Bolting Procedure Flowchart

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 Hot and Odd Bolting Procedure UKCS-SOP-027

1 Terminology

Dispensation for Area

Term Use of Term Infers
Must Legislative Requirement
Group Standard/Practice or
Golden Rule
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Covered by Term
All dispensations are to be
recorded and retained in eMOC
No dispensation can be granted.
Inform SPU EA/VP HSSE and
Engineering via AOM
Authorisation above the level of
North Sea Unit. Forward to VP
HSSE and Engineering/SPU EA
for referral to Group

Shall Minimum requirement Approval by VP HSSE and

stipulated at SPU/UK level Engineering/SPU EA
Should SPU/UK Best Practice or Approval by OIM or AOM
Recommended/Preferred option (onshore Terminals)

2 Purpose
The purpose of this procedure is to define the limits of application of the hot and odd
bolting techniques, the factors to be considered when evaluating the feasibility of its
use, and the preparation and execution of the procedure.
Notes: (1) Hot bolting is the sequential removal, cleaning, lubrication and refitting,
or replacement with new, of one bolt at a time in a flanged joint, when
the system is either within specified pressure limits or depressurised.
(2) Odd bolting is the sequential removal of alternate bolts from a flanged
joint when the system is shut down, isolated and at low pressure or
depressurised but not necessarily gas-free. (Odd bolting is normally
preceded by hot bolting.)
(3) The words ‘bolt(s)’ or ‘bolting’ includes bolts, stud bolts, studs, nuts and
washers, as appropriate.
WARNING: REMOVING, REPLACING OR RETIGHTENING BOLTS ON LIVE PIPING
AND EQUIPMENT IS POTENTIALLY HAZARDOUS. EXTREME
CAUTION NEEDS TO BE EXERCISED WHEN ASSESSING, PLANNING
AND CARRYING OUT THESE OPERATIONS.

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 UKCS-SOP-027 Hot and Odd Bolting Procedure

3 Scope
Refer to the Hot and Odd Bolting Flowchart shown in Figure 1.
This procedure shall be followed at all BP North Sea SPU UK sites, offshore and onshore.

3.1 Standard Requirements

The following standard requirements shall be met for proposed hot and odd bolting
activities on piping systems and piping connections at vessels:
• Lines shall contain utilities, air, diesel or firewater, or, if hydrocarbons, shall be
isolated and depressurised
• Joints shall be of a standard flanged design with a minimum of eight bolts
• The pressure in the piping or equipment shall be less than 60% of the maximum
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allowable pressure of the flange. For example, in the case of class designated
flanges, this would be 60% of the specified rating appropriate to the class, material
and operating temperature of the flange given in ASME B16.5 Pipe Flanges and
Flanged Fittings
• The temperature in the piping or equipment shall be less than 60°C

3.2 Specific Exclusions

Hot and odd bolting activities shall not be performed on:
• Lines containing steam, toxic chemicals or gas
• Hydrocarbon lines which are not isolated and depressurised
• Clamped flanges (eg Grayloc)

3.3 Approval for Exceptional Hot or Odd Bolting

In circumstances where the OIM or Site Manager considers that hot or odd bolting could
be safely performed out with the above criteria, and where there is no other practicable
alternative, a full Engineering Assessment by a competent, Multi-skilled Team is required
to be carried out together with the following actions:
(1) A Risk Assessment outlining rigorous control measures shall be conducted
(ie mitigation measures, drains, fire hoses etc).
(2) Before the work commences, approval shall be obtained from the Area Operations
Manager (AOM), who will review the risk assessment and seek endorsement from
the SPU Engineer Authority.
This includes the following cases:
• Non-standard flanged joints, eg those found on many heat exchanger head, tubesheet
or shell joints
• Joints in transmission pipelines (due to the potential for high external loadings)
• Use of proprietary temporary clamps on four bolt flanges on lines containing utilities,
air, diesel or firewater, or containing hydrocarbons if isolated and depressurised

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4 Application
4.1 General
The removal and replacement of flange bolts on live equipment is practiced for several
reasons including:
 Replacing corroded or damaged bolts
 Upgrading the material specifications/grades of bolts
 Minimising time spent freeing bolts during plant shutdowns
Any potential benefit arising from minimising time spent freeing bolts during plant
shutdowns shall be carefully weighed up against the risks. Marginal time savings during
shutdowns shall not be considered sufficient incentive for using hot bolting.
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Bolts in flanged joints that have been in service can seize or be difficult to remove.
Unscheduled time delays caused by problems in breaking flanged joints at the start
of maintenance programmes can be potentially detrimental, eg by extending the duration
of activities involving some hazard or by creating significant work scheduling
difficulties later.
Pre-planned hot and odd bolting may be considered as a possible answer to these
problems where better control of subsequent tasks (ie overall safety and efficiency)
justifies the use of the techniques.
When assessing applications for hot and odd bolting, management shall balance the
potential loss exposures in undertaking the activity against those associated with
unscheduled delays.

4.2 Potential Hazards

Note: Hot and odd bolting shall be performed under Integrated Safe System of Work
(ISSOW) Procedure (UKCS-SSW-002) and Safe Isolation and Reinstatement
of Plant (SIRP) (NSSPU-GP-44-40-1) control because of possible breaking
of containment.

4.2.1 Hot Bolting

In hot bolting there is a potential risk of leakage caused by:
 Reduced gasket compression during bolt removal
 Inadequate tightening on bolt replacement
 Gasket failure from overtightening of bolts on replacement

4.2.2 Odd Bolting

In odd bolting there is a potential risk of leakage caused by:
 Reduced gasket compression during bolt removal
 Inadvertent repressurisation of the equipment during and subsequent to odd bolting

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 UKCS-SOP-027 Hot and Odd Bolting Procedure

5 Responsibilities
5.1 Area Engineering Services Team Leaders (AESTLs)
AESTLs shall be responsible for:
 Operating in accordance with this procedure and self-regulation of its compliance
 Justifying any deviations, using a full Engineering Assessment (carried out by a
competent, Multi-skilled Team) and appropriate risk assessment techniques,
where local conditions may not permit the use of the defined hot or odd bolting
technique. Such deviations shall be formally approved by the AOM (or their formally
delegated nominee), endorsed by the SPU Engineering Authority, and recorded
together with the assessments and necessary additional precautions
 Maintaining a record system of completed Hot/Odd Bolting Certificates (refer to
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Figure 2) for all proposed activities, whether approved or rejected

 Appointing competent persons to take responsibility for performing the functions of
OIM/Site Manager, Area Authority, Performing Authority and Mechanical Responsible
Person for the site with regard to this procedure

5.2 OIMs/Site Managers

OIMs/Site Managers shall be responsible for:
 Endorsing the assessment and preparations, as identified in the Hot/Odd Bolting
Certificate (refer to Figure 2), by giving approval for the work to proceed
 Approving Risk Assessments
 Approving lessons learned

5.3 Area Authorities

Area Authorities shall be responsible for:
 Liaising closely with the Performing Authority to ensure all appropriate hazards and
controls have been identified
 Ensuring that the appropriate level of risk assessment has been carried out
 Ensuring that worksite inspections are carried out before, during and after the work
 Inspecting joints and confirming that bolting is mechanically complete
 Validating lessons learned

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For a usable version of this form click here.

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Figure 2 Hot/Odd Bolting Certificate

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 UKCS-SOP-027 Hot and Odd Bolting Procedure

5.4 Performing Authorities

Performing Authorities shall be responsible for:
 Ensuring that where other persons are involved in the work, they fully understand the
scope of the work and the hazards and controls for the job by holding a pre-job safety
toolbox meeting
 Ensuring that only work covered by the hot/odd bolting procedure takes place
 Participating in any Risk Assessment for the work, where required
 Ensuring that the worksite is kept in a clean and safe condition both during and upon
completion of the work
 Ensuring adequate handovers take place at shift and crew change periods with the
oncoming Performing Authority
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 Ensuring that lessons learned from the work are captured

5.5 Mechanical Responsible Persons

Note: Normally this would be the site Mechanical Technician.
Mechanical Responsible Persons shall be responsible for:
 Ensuring that the assessment and preparations are complete as identified in the
Hot/Odd Bolting Certificate (refer to Figure 2)

5.6 Multi-skilled Team

A Multi-skilled Team shall carry out the Engineering Assessment and be responsible for:
 Establishing that the proposed bolting operation can be performed safely by carrying
out an engineering review involving a formal risk assessment
 Establishing that there are no unacceptably high external loads and/or bending
moments acting on the joint

6 Planning
6.1 Introduction
Hot and odd bolting shall be planned in advance (as shown in Figure 1) and controlled
by the ISSOW system, engineering procedures, including the use of the Hot/Odd Bolting
Certificate shown in Figure 2, and any other job-specific instructions (eg Maximo) will be
used.

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6.2 Completion of Hot/Odd Bolting Certificate

An initial engineering review shall be carried out by the Mechanical Responsible Person
to establish that the proposed hot or odd bolting can be performed safely.
The review shall be carried out as listed in the Hot/Odd Bolting Certificate (refer to
Figure 2) as follows:
 Section 1 – Design Conditions (Documentation Check)
Covers the general suitability of the techniques for the proposed activity.
 Section 2 – Site Inspection
Covers the practicability of successfully accomplishing the task at the actual worksite.

6.2.1 Section 1 – Design Conditions

The following factors, as listed in the Hot/Odd Bolting Certificate (refer to Figure 2), shall
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be considered:
 Odd Bolting Maximum Operating Pressures:
Odd bolting shall only take place when the system is shut down and depressurised
to a maximum of 1bar.
Fluid temperatures shall not exceed 60°C. The appropriate Personal Protective
Equipment (PPE) shall be worn at all times during hot and odd bolting operations.
 Mechanical Considerations:
The mechanical details of the connection need careful consideration. The factors
to be assessed will include those listed in Table 1.

Detail Consideration
Number of bolts Flanges shall have a minimum of 8 bolts. Any proposed use
in the flange of proprietary temporary clamps on four bolt flanges shall be
subjected to a full Engineering Assessment.
Type of flange These techniques are only applicable to standard bolted
flanges unless subjected to a full Engineering Assessment.
Joints in risers Special checks required due to wave loadings etc. Hot or odd
bolting shall not be attempted on a joint in risers without a
full Engineering Assessment.
Piping supports The position of piping supports and the support they provide
for the local section shall be reviewed. The requirement for
additional temporary supports shall be assessed.
Expansion bellows Hot or odd bolting shall not be attempted on an expansion
bellows without a full Engineering Assessment.

Table 1 Factors to be Assessed

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 UKCS-SOP-027 Hot and Odd Bolting Procedure

6.2.2 Section 2 – Site Inspection

The Site Inspection covers the detailed inspection of the actual job site before approval
of the requested activity. This assessment shall include the following factors as listed
in Section 2 of the Hot/Odd Bolting Certificate (refer to Figure 2):
 Condition of Joints and Bolting
The general condition of the joint(s) intended to be hot or odd bolted. If there
is damage that may have reduced the strength of bolting, or any exterior indication
that the joint may be overly corroded, then hot or odd bolting shall not be performed.
 Condition of Pipe Supports
The adequacy of pipe supports in the vicinity of the joint(s) (condition and functionality
are relevant). The supports shall be in good condition and shall be inspected visually
to confirm that they are in fact carrying the piping loads.
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 Vibration
There shall be no vibration of the piping at the joint.
 Access Conditions
There shall be safe access and egress to and from the worksite under normal and
emergency conditions.
 Maintenance History (if applicable)
Previous experience with the joint or joints of similar type.
This detailed information will enable concise written instructions to be prepared
for the task.
The conditions of the line or vessel shall be held stable throughout the hot or odd bolting
work. Joints shall not be subjected to high external loads, high temperature
or significant load variations (eg no possibility of large increases or decreases
of operating pressure) during hot and odd bolting.
Safeguards (a copy of the relevant Hot/Odd Bolting Certificate (refer to Figure 2) shall
be kept with the ISSOW Work Control Certificate (WCC)) shall be implemented
to ensure that lines or joints cannot be fully repressurised until they have been returned
to the normal fully-bolted state.

6.3 Preparations
Thorough preparations shall be made for every hot and odd bolting activity, as follows:
(1) Hot/Odd Bolting Certificate
Refer to Figure 2.
A certificate shall be initiated for each proposed activity and this, plus any
attachments, shall form the specific job instructions. The certificate shall contain
the details of the primary and secondary assessments already discussed, plus the
following preparatory information.
Note: For multiple joints, at the same pressure, on a line or system,
one certificate may be used with the flanges identified on a sketch
attached to the certificate.

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The Mechanical Responsible Person shall endorse the Hot/Odd Bolting Certificate
(refer to Figure 2) prior to application for a WCC. This endorsement will signify
that all necessary assessment and other preparatory work has been performed.
The OIM/Site Manager shall approve the certificate together with its associated
WCC.
Note: Where odd bolting follows hot bolting, a copy of the signed-off Hot Bolting
Certificate shall be attached to the Odd Bolting Certificate.
(2) Access
The area shall be reviewed for accessibility to ensure that adequate routes are
available in the event of pipe spring or uncontrollable leakage.
(3) Safety Equipment
Appropriate protective and safety equipment (as specified by the Area Authority
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on the WCC) shall be worn in case of leakage. The need for standby cover shall
be assessed.
(4) Other Equipment and Materials
From site examination of the joint, the need or allowance for any additional
equipment or replacement bolting materials (which shall comply with the relevant
piping specification) will be defined, checked and made available onsite before
starting the work.
(5) Bolt Removal and Remaking
Flogging (either manually or by using air impact wrenches) shall not be used when
tightening the bolts. Provision may be made for hydraulic tensioning of bolts
greater than 25mm (1in). For smaller bolts, calibrated torque wrenches may be
used subject to existing pipework and vessel specifications. Flogging off old bolts
is permissible for removal subject to assessment of potential personal injuries.
(6) Instruction
All personnel involved in the operation shall be fully instructed regarding the
execution and possible hazards of the operation. An Operator should be in
attendance with radio contact to the control room.
The Performing Authority shall be instructed that if a leak develops during either
hot or odd bolting, particularly when a bolt is first slackened, the bolt should be
retensioned and advice sought. During hot bolting, the flange shall not be left
unattended whilst any bolts are not in place. If required, the flange can be taped
around its circumference to aid in the detection of vapour leaks.
(7) Contingency Plan
The location and condition (valve seal integrity) of the nearest upstream and
downstream isolation valves shall be ascertained prior to commencing work.
Operations personnel shall have a contingency plan should shut-in be required
due to uncontrollable leakage.
The contingency plan shall address the means of communication for raising
alarms, local Emergency Shutdown (ESD) arrangements and emergency response,
including having rescue equipment locally on standby.

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 UKCS-SOP-027 Hot and Odd Bolting Procedure

7 Procedures
7.1 Hot Bolting Procedure
Cold cutting of bolts on non-hydrocarbon lines can be used, but the blowout potential
of the gasket and its ability to be re-tightened shall be considered and included in the
Contingency Plan.
Good communications with operations personnel are particularly important during this
procedure.
Flanges to be hot/odd bolted shall be physically marked either by a paint marker or tag
prior to commencement of the job.
Bolt removal, examination and replacement shall be as follows:
(1) Before work starts, the Area Authority shall check that:
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(a) All necessary materials, equipment and personnel are onsite.

(b) All relevant procedural requirements have been met.
(c) Appropriate safeguards are in place.
(d) The pressure in the piping and equipment is at the specified reduced value
and that process conditions are stable.
(2) The Performing Authority shall check that:
(a) Each of the existing bolts is tight to the correct torque, if known (to ensure
that bolts have not relaxed in service).
(b) Any abnormal conditions, such as loose bolts, found at this stage are
reported to the Area Authority.
(3) Hot bolting shall be carried out on only one bolt at a time, in the sequence
specified in Figure 3 or other specific job instructions.
(4) Each bolt, complete with nuts, shall be removed, examined, cleaned and
lubricated for reuse. Damaged bolts shall be disposed of and replaced by new
items of the correct specification. If in doubt, the bolting shall be replaced.
Exposed flange surfaces shall be cleaned and the area under the nuts thoroughly
lubricated.
(5) The bolt shall be correctly torque-tightened or tensioned to the value obtained
prior to starting the task. Initial retightening of refitted bolts shall not introduce
additional local compression of the gasket.
(6) After all bolts have been replaced, a final tightness check shall be carried out in the
sequence specified in Figure 3.
(7) The Area Authority shall inspect the completed job and sign the certificate.
(Any comments should be attached to the certificate.)
(8) On completion of the work, the maintenance history shall be updated (the flange
may also be tagged identifying work carried out).

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HOT BOLTING

During hot bolting, bolts will be removed

and replaced in the following numeric order:

3 3
9 7
7 5

5 11
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8 BOLT 12 BOLT
1 FLANGE 2 1 FLANGE 2

12 6
6 8
8 10
4 4

3
13 11
5 7

9 15

16 BOLT
1 FLANGE 2

16 10

8 6
12 14
4

13 3 17 11 3 15
9 7 19 21
7 5
5 11
23 17
19 15
14 9
20 BOLT 24 BOLT
1 FLANGE 2 1 FLANGE 2

16 20 10 13

12 6 18 24

8 10 6 8
18 14 22 20
4 16 4 12

Final retightening should also follow above number sequence.

UKCSSOP027_006.ai

Figure 3 Hot Bolting Removal and Tightening Sequence

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 UKCS-SOP-027 Hot and Odd Bolting Procedure

7.2 Odd Bolting Procedure

Good communications with operations personnel are particularly important during this
procedure.
Flanges to be hot/odd bolted shall be physically marked either by a paint marker or tag
prior to commencement of the job.
Bolt removal shall be as follows:
(1) Before work starts, the Area Authority shall check that:
(a) All necessary materials, equipment and personnel are onsite.
(b) All relevant procedural requirements have been met.
(c) Appropriate safeguards are in place.
(2) Normally, odd bolting is preceded by hot bolting (to ensure that bolts to be
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removed are in good condition and reasonably free to move). The Area Authority
shall check the signed-off Hot Bolting Certificate for any comments that could be
relevant to the odd bolting activity.
(3) The Performing Authority shall check that:
(a) The pressure in the piping and equipment is at the specified reduced value
and that process conditions are stable.
(b) Each of the existing bolts is tight to the correct torque, if known (to ensure
that bolts have not relaxed in service).
(c) Any abnormal conditions, such as loose bolts, found at this stage are
reported to the Area Authority.
(4) Bolt removal shall be carried out according to the methods specified by the
Mechanical Responsible Person in the job instructions or on the certificate.
(5) The sequence of bolt removal shall be as specified in Figure 4 or other specific job
instructions and/or on the certificate.
(6) The Area Authority shall inspect the completed job and sign the certificate.
The signed-off certificate will form a record of the odd bolted status of the joint(s).
(Any comments should be attached to the certificate.)
(7) On completion of the work, the maintenance history shall be updated (the flange
may also be tagged identifying work carried out).

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ODD BOLTING

Only alternate bolts removed. Bolts should

be replaced in the following numeric order:

3 1
3 1
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8 BOLT 12 BOLT
FLANGE 5 FLANGE 6

2 4
2 4

7 1

3 6

16 BOLT
FLANGE

5 4

2 8

8 1 9 1
7 6
3 6

3 11
20 BOLT 24 BOLT
10 FLANGE 9 FLANGE
12 4

5 4
5 8
2 7 2 10

Indicates bolts which must be left in place.

UKCSSOP027_007.ai

Figure 4 Odd Bolting Bolt Removal and Tightening Sequence

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 Hot and Odd Bolting Procedure UKCS-SOP-027

Addendum 1
Terms of Reference and Monitoring Protocol

1 Terms of Reference
To view the Terms of Reference, please click HERE.

2 Monitoring Protocol
To view the Monitoring Protocol, please click HERE.
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Terms of Reference and Monitoring Protocol

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