RUMAILA PROJECT

Document
Number:

101763KR-C-G0-G000-CM-MET-0001

Document
Title:

Method Statement for Hot Bolting.

Project Title:

QA/MOV-71/72 Tee Piece.

Class

A01

Tag Nos
(if applicable)
Contractor:

AL-KARRAR Engineering Co. For General Contracting Ltd.

Contractor
Document No:

A01

ISSUED FOR REVIEW

Rev.

Revision Description
.

Rev

Date

Originated

Reviewed

A01

Approved

AL-KARRAR Engineering Co.

For General Contracting Ltd

Radiography Procedures

METHODOLOGY

When contemplating hot bolting a number of factors need to be considered. These

include, but are not limited to:
The piping system and the system's operating pressures and temperatures.
Flange joints considered for hot bolting should have a minimum of 8 (eight) bolts. The
bolt material should have a minimum strength equal to or greater than grades B7/2H
Prior to the commencement of work, the supervisor should review the maintenance
history of the joint under consideration, and any joints of a similar type which have
been hot bolted in the past.
The supervisor should also carry out a visual assessment of the joint. Hot bolting
should not be carried out on joints which show significant signs of corrosion or
necking, or which have worn or cracked threads on the fasteners.
Hot bolting should only be attempted under operating conditions when the history of
the flange assembly is known, i.e. records exist for the bolt load.
The consequences of joint leakage during hot bolting should be considered (for
example, toxicity, flammability and temperature of escaping fluids) and all necessary
precautions taken. Contingency plans should also be put in place for an escape or
emergency, e.g. means of communications and provision of standby equipment.
Pipework within the vicinity of the joint to be hot bolted should also be reviewed. Pipe
supports for the local section should be checked to ascertain whether they are taking
the load on the pipe, along with their overall condition. If the pipework displays any
significant signs of vibration around the specific flange, then hot bolting should not
be considered as an option.
The site supervisor shall check that all the necessary personnel, materials and
equipment are at the worksite.
Each bolt shall be checked for tightness, with any abnormal conditions, such as loose
bolts, reported to the supervisor.

101763KR-C-GO-G000-IX-PRO-0001

Rev A01

Page 2 of 4

AL-KARRAR Engineering Co.

For General Contracting Ltd

Radiography Procedures

Carry out hot bolting on one bolt at a time in accordance with the operator's correct
sequence. Remove, examine, clean and lubricate each bolt, complete with nuts, for
reuse. Any damaged bolts or nuts shall be disposed of and replaced with new items
to the correct piping specification. If there is any doubt, the materials shall be
replaced. All exposed flange surfaces must be cleaned. And the area under the nuts
lubricated.

Note: Bolt cutting by any hot methods, including burning and grinding, is not usually
permitted during hot bolting operations. Any cold bolt cutting, including hydraulic nut
splitting, is usually only permitted by specific approval of the relevant authority.

Ensure that the bolt has been correctly tightened before moving onto the next bolt in
the sequence. Initial retightening of refitted bolts shall not introduce additional local
compression of the gasket.
After all the bolts have been replaced, a final tightness check shall be carried out
again.

This work will be executed on flanges of live facilities, therefore in order to avoid potential
risk of water leakage rising through the flanges connection, the bolts shall be released
and reinstated one by one. Sequence of bolts tightening arranged as such way to
minimize the risk as defined in work steps hereafter.

Due to short length of existing bolt, torque wrench or hammer wrench will be used for
bolting / unbolting. Prior to unbolting a complete check of all new bolts nuts (number +
diameter + length + material) must be performed. Thread of existing bolts shall be
cleaned up first from any dirt, paint or corrosion by means of paints removal and to be
brushed by hand wire brush.

After one bolt has been released, then the all threads of bolt and nut shall be properly
greased prior to reinstatement.

101763KR-C-GO-G000-IX-PRO-0001

Rev A01

Page 3 of 4

AL-KARRAR Engineering Co.

For General Contracting Ltd

Radiography Procedures

Unbolting and bolting shall be done according to the following steps:

1.
2.
3.
4.
5.
6.
7.
8.
9.

Smear the bolt no. 1 until the last bolt by paint removal and leave it for about 15 minutes.

Clan up the bolt by hand wire brush from dirt, paint or corrosion.
Install torque wrench or hammer wrench on the bolt.
Loosen the bolts nut just a little bit, then check this flange connection if there is
water leakage, especially at the position of bolt being loosened.
If the condition is safe, then continue unbolting process while monitoring.
Grease all threads of bolt and nuts.
Reinstate the bolt and properly tighten it using torque wrench.
Mark the bolt that has been completed using marker.
For hot bolting work, the bolts shall be released & reinstated one by one.

101763KR-C-GO-G000-IX-PRO-0001

Rev A01

Page 4 of 4