Gom Region Hot Bolting Safe Work Practice (SWP) : Document Number: CD # Ups-Us-Sw-Gom-Hse-Doc-00112-2

GoM Region Hot Bolting Safe Work Practice (SWP)
Page 1 of 5

Document Number: CD # UPS-US-SW-GOM-HSE-DOC-00112-2
Document Authority:
GoM Ops & OMS

Director
Document Custodian: GoM CoW Authority
Scope:
GoM H&S
Doc Admin:
GoM H&S Document

Management Administrator
Issue Date:
01/25/02
Issuing Dept:
GoM H&S
Revision Date:
06/15/12
Control Tier:
2 GoM H&S
Next Review Date:
03/01/15
OMS Element:
4.5 Control of Work
Purpose/Scope
Procedures
2.1
Hot Bolting
The purpose of this Safe Work Practice (SWP) is to outline the requirements for conducting safe Hot
Bolting operations.
Hot Bolting allows for corroding studs and nuts to be removed as part of preventative maintenance while
the line is in service. A risk assessment shall be performed prior to Hot Bolting to confirm the flange will
not leak or fail during the procedure.
Nuts/studs shall be removed and replaced immediately, one at a time, in a specified cross-bolting
sequence/pattern.
WARNING:
1. Prior to removing any nut/stud, all existing nuts/studs shall be checked for tightness by
torqueing the flanged joint to the manufacturer specifications.
2. Hot Bolting and Hot Work are not allowed within 100 feet of each other.
All new studs and nuts shall be torqued according to the manufacturer's specifications.
A BP representative shall be present during all Hot Bolting activities.
Working on live piping and equipment should only be done when the advantages have been assessed
against the potential risks. The risk assessment shall include a review of:
Design specifications of the flanged joint, including bolting and gasket specifications.
Contents of the piping or equipment (e.g., the flammability and/or toxicity of the process fluid).
Design and operating pressures and temperatures; confirming that the pressure in the
piping/equipment is at the specified reduced value and that the process conditions are stable.
The possibility and consequences of a process upset occurring.
NOTE: The location and condition of the nearest upstream and downstream isolation valves relative to
the joint shall be identified prior to commencing the work.
The position and functionality of pipe supports relative to the flanged joint.
NOTE: From a mechanical standpoint, there should be no unacceptably high external loads and/or
bending moments acting on the joint nor should be no significant vibration of the piping at the
joint.
Revision Date: 06/15/12
Control Tier: 2-GoM HSSE
Document Number: UPS-US-SW-GoM-HSE-DOC-00112-2
Print Date: 9/20/2012
PAPER COPIES ARE UNCONTROLLED. THIS COPY VALID ONLY AT THE TIME OF PRINTING.
Page 2 of 5
The position and type of flexible expansion joint affecting the flanged joint.
Maintenance history of the joint.
Personnel access and egress-consideration should be given to the accessibility of the area and to
confirming that adequate escape routes are available should the pipe spring or should leakage occur.
WARNING: Hot Work (cutting or burning) on seized nuts/studs, shall not be allowed on flanges in
service. Cold cutting is permissible and should be considered.
Possible degradation of the nuts/studs (e.g., corrosion, stress corrosion cracking, fatigue).
Possible degradation of the gasket.
2.1.1 Potential Risk of Leakage

In Hot Bolting, there is a potential risk of leakage caused by:
Reduced gasket compression during bolt removal,
Inadequate tightening on bolt replacement, or
Gasket failure from over-tightening of bolts on replacement
2.1.2 Allowable Flanges

The practice of Hot Bolting shall only be allowed for those flanges indicated in Table 1 (ANSI class
flanges) and Table 2 (API class flanges).
NOTE:
1. Some flanges require a decreased pressure rating during Hot Bolting (from 9 percent to 72
percent less than normal pressure rating) or are not allowed at all (ANSI 150 class flanges).
Use Table 1 and Table 2 in conjunction with Hot Bolting safety practices to enhance
personnel safety and code compliance.
2. Flat-face flanges are not addressed in this manual. If Hot Bolting is necessary, a
Management of Change and hazard assessment shall be performed.
Table 1: ANSI Class Flanges

Normal
Pipe
Size
ANSI
Class
150
Flange
Type*
Normal
Bolt
Count
Normal
PSI
Max
RF
285
300
RF
600
RF
600
900
2
2
Hot
Bolt
Hot Bolt
Allowed
Comments
No
Insufficient gasket-seating force
740
740
Yes
1480
1480
Yes
RJ
1480
1480
Yes
RJ
1500
RJ
3705
2850
Yes
23% pressure reduction
2500
RJ
6170
3700
Yes
PSI
Max
Not available. Use 2 ANSI 1500

Normal
Pipe
Size
ANSI
Class
150
300
3
3
Flange
Type*
Page 3 of 5
Normal
Bolt
Count
Normal
PSI
Max
Hot
Bolt
Hot Bolt
Allowed
Comments
RF
285
RF
740
No
740
Yes
600
RF
1480
1325
Yes
600
RJ
1480
1325
Yes
900
RJ
2220
1975
Yes
1500
RJ
3705
2223
Yes
2500
RJ
6170
3680
Yes
150
RF
285
No
300
RF
740
740
Yes
600
RF
1480
1350
Yes
600
RJ
1480
1350
Yes
900
RJ
2220
2220
Yes
1500
RJ
3705
3705
Yes
150
RF
285
No
300
RF
12
740
740
Yes
600
RF
12
1480
1480
Yes
600
RJ
12
1480
1480
Yes
900
RJ
12
2220
2220
Yes
1500
RJ
12
3705
3705
Yes
150
RF
285
No
300
RF
12
740
740
Yes
600
RF
12
1480
1325
Yes
600
RJ
12
1480
1325
Yes
900
RJ
12
2220
2220
Yes
1500
RJ
12
3705
3705
Yes
10
150
RF
12
285
No
10
300
RF
16
740
740
Yes
10
600
RF
16
1480
1480
Yes
10
600
RJ
16
1480
1480
Yes
12
150
RF
12
285
No
12
300
RF
16
740
740
Yes
12
600
RF
20
1480
1480
Yes
12
600
RJ
20
1480
1480
Yes
16
150
RF
16
285
No
16
300
RF
20
740
740
Yes
16
600
RF
20
1480
1350
Yes
16
600
RJ
20
1480
1480
Yes
PSI
Max


Normal
Pipe
Size
ANSI
Class
18
150
18
300
18
Flange
Type*
Page 4 of 5
Normal
Bolt
Count
Normal
PSI
Max
Hot
Bolt
Hot Bolt
Allowed
Comments
RF
16
285
RF
24
740
No
740
Yes
600
RF
20
1480
1250
Yes
18
600
RJ
20
1480
1480
Yes
20
150
RF
20
285
No
20
300
RF
24
740
740
Yes
20
600
RF
24
1480
1300
Yes
20
600
RJ
24
1480
1480
Yes
24
150
RF
20
285
No
24
300
RF
24
740
740
Yes
24
600
RF
24
1480
1300
Yes
24
600
RJ
24
1480
1480
Yes
PSI
Max

Table 2: API Class Flanges

Normal
Pipe
Size
ANSI
Class
1-13/16
1-13/16
10K
10K
2-1/16
2-1/16
2-1/16
Flange
Type*
Normal
Bolt
Count
Normal
PSI
Max
RJ
RJ
8
8
10000
15000
5K
10K
15K
RJ
RJ
RJ
8
8
8
2-9/16
2-9/16
2-9/16
5K
10K
15K
RJ
RJ
RJ
3-1/8
3-1/8
3-1/8
5K
10K
15K
4-1/16
4-1/16
4-1/16
Hot
Bolt
Hot Bolt
Allowed
Comments
4100
5700
Yes
Yes

5000
10000
15000
2900
3350
4650
Yes
Yes
Yes

8
8
8
5000
10000
15000
3150
3350
4400
Yes
Yes
Yes

RJ
RJ
RJ
8
8
8
5000
10000
15000
2850
3300
4400
Yes
Yes
Yes

5K
10K
15K
RJ
RJ
RJ
8
8
8
5000
10000
15000
2750
2800
4400
Yes
Yes
Yes

5-1/8
5-1/8
5K
10K
RJ
RJ
8
12
5000
10000
3075
3100
Yes
Yes

7-1/16
7-1/16
7-1/16
5K
10K
15K
RJ
RJ
RJ
12
12
16
5000
10000
15000
3300
3400
4650
Yes
Yes
Yes

PSI
Max

Page 5 of 5
NOTE: Pressure ratings are for API 6B and 6BX flanges made of American Society for Testing
Materials (ASTM) A-105 material (for API 6B flanges 5K rating or less) or AIS 4130 (for API
6BX flanges 10K and 15K rating) at -20F to 200F, and with A193 Grade B7 bolts. Calculations
are in accordance with ANSI B31.3.
*Above tables refer to weld neck flanges
Key Documents
ANSI B31.3, Petroleum Refining Piping

API 6B, Flanges
API 6BX, Flanges
Revision Log
Revision Date
Authority
Custodian
Revision Details
06/15/12
GoM H&S
Director
GoM Safety
Programs Lead
Reformatted document to meet new GoM

document control template standardization
guidelines.
05/01/09
GoM HSSE
Director
GoM HSSE
Programs
Manager
Table 1, the Comment Not available, use 2

ANSI 1500 on Line with 2 Pipe Size, 600
ANSI Class, RJ should be moved down one
line to correspond with 2, 900, RJ line.
06/01/08
GoM HSSE
Director
GoM HSSE
Programs
Manager
Formatting and minor edits for clarification
02/28/06
S. Garner/ S. Tink/
R. DeLeonardis/ C.
Jackson
Kathy Kanocz
Added guidance on risk assessment. Added

more sizes and ratings based on engineered
calculations. Changed CD # from 10097 to
UPS-US-SW-GOM-HSE-DOC-00112-2 to
conform to new numbering nomenclature in
the new GoM HSSE doc base. Changed 3
authorities and 1 custodian.
01/25/02
S. Garner/ B.
Herbert/ R. White/
S. Flynn
Ray Britt
Initial issue as controlled document. Prior

revision history located in hard-


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