ASME PCC-2–2018

Article 311
Hot and Half Bolting Removal Procedures

311-1 DESCRIPTION 311-2 LIMITATIONS

311-1.1 Introduction 311-2.1 Additional Requirements

Bolts in flanged joints that have been in service can be Part 1 of this Standard, “Scope, Organization, and
difficult to remove. Such difficulties at the start of shut- Intent,” contains additional requirements and limitations.
downs for plant maintenance can result in costly schedule This Article shall be used in conjunction with Part 1.
interruptions, or extend the duration of activities invol-
ving some hazard. The use of hot and half bolting removal 311-2.2 Risks Associated With Hot and Half
procedures may be considered as a possible solution. Bolting

311-1.2 Hot Bolting Although hot bolting and half bolting removal proce-
dures can reduce plant downtime, they are potentially
Hot bolting is the sequential removal and replacement hazardous and therefore caution shall be exercised in
of bolts on flanged joints while under reduced operating their planning and execution. In considering potential
pressure (see para. 311-3.4). It is carried out one bolt at a applications for hot bolting and half bolting removal
time in a predetermined cross pattern sequence. Each procedures, any potential benefits from these activities
replaced bolt is fully tensioned before the next one is should be carefully weighed against the risks (see
removed. para. 311-3.1).
Hot bolting can be used to clean, lubricate, and reinstall
existing bolts for preshutdown activities, replace 311-2.2.1 Risks Associated With Hot Bolting. When
corroded or damaged bolts, or upgrade the material spec- conducting hot bolting removal procedures, the risks
ification or grade of bolts. of fluid leakage are increased due to increased bolting
stresses and relaxation of gasket compression, both
NOTE: Hot bolting can also be used to check residual bolt stress potentially resulting in joint leakage or gasket segment
after a period of operation, or to retighten loose bolts. Hot bolting
blowout.
for these purposes is beyond the scope of this Standard.
311-2.2.2 Risks Associated With Half Bolting. When
311-1.3 Half Bolting conducting half bolting removal procedures, the risks of
fluid leakage are increased due to reduced gasket
Half bolting is the removal of every other bolt (so the compression and the possibility that the system may inad-
flange is left with half the number of bolts) during plant vertently be repressurized. For this reason, the system
depressurization, usually when the system is close to pressure at which half bolting is conducted should be
atmospheric pressure. well below design pressure and preferably at or near
NOTE: Half bolting is also sometimes referred to as skip bolting atmospheric pressure with local management controls
or odd bolting. in place to prevent repressurization.

311-1.4 Definition of Bolt 311-2.3 Procedures and Safe Work Practices

Bolt as used herein is an all-inclusive term for any type The requirements and guidance for hot bolting and half
of threaded fastener that can be used in a pressure- bolting removal provided in this Article are generic in
boundary bolted flange joint assembly such as a bolt, nature and shall be combined with a job-specific proce-
stud, studbolt, cap screw, etc. dure along with other appropriate plant safe work
practices.

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311-3 DESIGN (c) the presence of external loads and/or bending

moments on the flange and the role they play on the
311-3.1 Engineering and Risk Analysis flange pressure carrying capability
An engineering and risk analysis of the proposed hot NOTE: It is recommended that the external axial loads and
bolting or half bolting removal operation shall be external bending moments acting across the flange be conser-
vatively converted into equivalent pressure. This total equiva-
carried out to establish that the operation can be
lent pressure plus the design pressure of the system under
performed safely; e.g., establish that no unacceptably consideration becomes the pressure to be used in the risk
high external loads and/or bending moments are analysis.
acting on the joint that could cause leakage or gasket
blowout during the operation. The analysis should (d) the reduction of effective minimum gasket
consider, as a minimum, the following: compressive stress between bolts associated with bolt
(a) contents of the piping or equipment removal; e.g., that sufficient loading remains on the
(b) design and operating pressures and temperatures gasket to ensure that it maintains a seal
(c) possible upset conditions
(d) bending moment on joint (see para. 311-3.2.1)
311-3.4 Maximum Pressure/Hot Bolting
(e) position and functionality of piping supports Unless otherwise justified by an engineering and risk
(f) position and type of expansion bellows analysis, hot bolting may be performed only when the
(g) maintenance history of the joint operating pressure is equal to or less than 50% of
(h) experience with hot or half bolting procedure appli- maximum pressure allowed as determined in para.
cation to similar joints 311-3.3.
(i) the target torque used in joint assembly
311-3.4.1 Confirming Reduced Pressure Prior to Hot
(j) confined vs. unconfined gasket type
Bolting. Confirmation that the pressure has been reduced
NOTE: A spiral wound gasket with a centering ring is consid- and that repressurization is not practicable shall be
ered to be a confined gasket. obtained from operations personnel before the hot
(k) through bolted vs. bolts studded unto tapped holes bolting removal operation is started.
(see para. 311-3.6) NOTE: In paras. 311-3.4.1 and 311-3.5.1,“not practicable” means
(l) gasket material/thickness that sufficient controls are in place to ensure repressurization
(m) condition of flange will not occur until the system is returned to a status when it is
(n) condition of bolts; including consideration whether safe to do so.
the necessary bolt stress is sufficient, or overstressed (see
paras. 311-4.1.6 and 311-4.1.7) 311-3.5 Maximum Pressure/Half Bolting
(o) condition of nuts (see paras. 311-4.1.6 and 311-
4.1.7) Unless otherwise justified by an engineering and risk
analysis, half bolting may be performed only during
311-3.2 Minimum Number of Flange Bolts depressurization when the pressure is equal to or less
than 25% of the maximum allowable pressure or 50
Unless the results of the engineering and risk analysis psig, whichever is lower, and when low pressure
establish that the consequences of either joint leakage or steam, air, or nitrogen (also see para. 311-4.1.5) is the
gasket blowout are acceptable, flanges should have a purging media.
minimum of eight bolts.
NOTE: If the fluid contents are such that there is low risk of injury
311-3.2.1 Bending Moments on ASME B16.5 Class 150 associated with accidental contact, the need for purging may be
Flanges. The 8-bolt Class 150 B16.5 flange is recognized reviewed for deletion.
as being uniquely under-bolted and thereby can only
accommodate modest external bending moments, a 311-3.5.1 Confirming Reduced Pressure Prior to Half
consideration in the risk analysis. Bolting. Confirmation that the pressure has been reduced
and that repressurization is not practicable shall be
311-3.3 Determining Maximum Pressures When obtained from operations personnel before the half
Conducting Hot/Half Bolting bolting removal operation is started.

The maximum pressure allowed while conducting 311-3.6 Tapped Holes — Use of Hot Bolting
either operation shall take due consideration of
(a) the applicable pressure-coincident temperature If bolts stud into tapped holes, the use of the hot bolting
rating for standard flanges (such as ASME 16.5 or procedure is not recommended unless it is known that the
ASME B16.47) threads on the studded end of the bolt have been relieved
(b) the calculated maximum allowable pressure per the to eliminate the possibility of damaging the tapped
applicable construction code for nonstandard flanges threads when the bolt is backed out.

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Even if this thread relief has been provided, it should be minimum required bolt load for leak tightness and an
recognized that studded joints are inherently more sensi- assessment of the possible bolt stress may be required
tive to reduction in bolt prestress due to normal embed- to ensure the bolts have sufficient load carrying capability.
ment and gasket creep effects. Accordingly, the probability
of a leak/gasket blowout is greater during either a hot or 311-4.2 Execution
half bolting operation than for a counterpart through- 311-4.2.1 Check of Existing Bolts for Tightness. To
bolted joint. anticipate flange bolt relaxation, every bolt shall be
checked for tightness prior to removing the first bolt.
311-4 FABRICATION Bolt tightness may be checked by applying torque with
either a hand wrench or a hydraulic torque wrench.
311-4.1 Preparation Do not use hammer (slug) wrenches.
311-4.1.1 Personnel Protective Equipment/ 311-4.2.2 Sequence of Bolt Changeout. When hot
Emergency Planning. Appropriate protective and bolting, the bolts shall be changed out one at a time in
safety equipment shall be worn in case of leakage. The a proper tightening sequence (see ASME PCC-1, Table
need for emergency standby and contingency planning 4). The numbering system for the appropriate tightening
shall also be considered. sequence should be marked on the flange in a readily
311-4.1.2 Access Considerations. Consideration shall visible location before starting to remove any bolts.
be given to the accessibility of the area and that adequate 311-4.2.3 Considerations Relative to In-Service vs.
escape routes are available should uncontrolled flange Pre-Shutdown. The provisions of paras. 311-4.2.4
leakage occur. through 311-4.2.7 may be more applicable when the
311-4.1.3 Location and Condition of Isolation Valves. flange is intended to remain in service, as opposed to
The location and condition of the nearest upstream and immediately prior to shutdown. This should be considered
downstream isolation valves shall be ascertained prior to in the engineering and risk analysis (see para. 311-3.1).
commencing work. Operations personnel shall have a 311-4.2.4 Cleaning and Lubrication of Surfaces. As
contingency plan for the isolation of the joint, which bolts and nuts are removed, the surface of the flanges
addresses the need to block in or depressurize the equip- where contact is made with the nuts should be wire or
ment rapidly should an uncontrollable leak occur. power brushed clean (remove protrusions, spot face if
311-4.1.4 Identification of Emergency Facilities. As required). Proper lubrication with an approved lubricant
necessary, emergency facilities such as safety showers should be applied to the friction surfaces of the bolt
and eye baths should be identified and locations made assembly. This includes the threads and all bearing
known to personnel involved in the work. surfaces of the nuts except for the surface between the
nut and the flange at the rear of the joint (on the opposite
311-4.1.5 Consideration of Nitrogen Hazards. If side of the flange from the torque wrench), where it is
nitrogen is used as a purging medium, consideration beneficial to allow friction to develop between the
shall be given to protection of personnel should a leak bearing surfaces.
occur in a confined space.
311-4.2.5 Hand Tightening and Baseline Bolt Length
311-4.1.6 Inspection of the Flange Assembly. A thor- Readings. Install bolts and nuts hand tight, with the
ough inspection of the flange assembly should be marked ends of the bolts and nuts located on the same
conducted to verify the integrity of the flange and its side of the joint and facing outward to facilitate inspection.
bolting, with consideration given to the following: If ultrasonic elongation control is to be used, initial bolt
(a) deterioration of the bolts and nuts, such as necking length readings should be taken and recorded at this time.
(corrosion thinning), worn threads, or cracking
(b) the ability of the gasket to be retightened and its 311-4.2.6 First Pass Torquing. Before new bolts/nuts
blowout potential are installed, check to determine that the nuts run freely by
(c) deterioration of the gasket, and the potential of hand past where they will come to rest after tightening. If
gasket failure due to disturbance or retightening nuts will not turn freely by hand, check for cause and make
(d) verification of sufficient thread engagement before necessary corrections/replacements.
half bolting of studded flanges, e.g., by ultrasonic measure- As each new bolt is installed, tighten the bolt using the
ment of stud length target torque value. Continue this process for each bolt in
the appropriate sequential pattern. If ultrasonic elonga-
311-4.1.7 Assessment of Existing Bolt Load tion control is to be used, readings should be taken after
Capability. If deterioration of bolts and nuts [see para. the first eight bolts have been replaced, and the torque
311-4.1.6(a)] is found, consideration shall be given to values adjusted, if necessary. If the adjusted torque
the safety aspects of bolt removal and the increased value is substantially higher than that used for the first
load on the remaining bolts. An analysis of the

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eight bolts, these bolts should be retorqued using the new 311-5 EXAMINATION
torque value.
NOTE: Differential thermal expansion may cause a loss of bolt 311-5.1 Examination for Workmanship and
load during the cooldown of hot flanges (see ASME PCC-1, section Leakage
12). This should be considered in determining the hot reas-
sembly bolt load. In addition, consideration should be given
Within the context of these requirements, examination
to allowing replacement bolts to reach their operating tempera- consists of an in-process visual check for good workman-
ture prior to final tightening. ship and an in-service visual check for signs of leakage.

311-4.2.7 Final Torquing. After each tightening round, 311-5.2 Examination of Bolts for Proper Material
take measurements around the circumference of the gap Specification
between flanges with a vernier or caliper to verify that the The markings on the bolts should be visually checked to
flanges are being brought together evenly (see ASME PCC- verify that the correct material is being used. This may be
1, para. 11.1). supplemented with PMI if additional assurance of correct
After the first pass torquing all bolts to the target torque material is desired.
value in an appropriate sequential order, one of the
following actions shall be required, depending upon
whether or not ultrasonic elongation control is used:
311-6 TESTING
(a) Tighten all bolts again using the same torque value There are no testing requirements associated with this
and following the sequential order from the first pass, Article.
followed by one or more passes using the target
torque value in a rotational order. 311-7 REFERENCES ð18Þ
(b) Take ultrasonic readings and adjust the torque
value, if necessary. Then, if the torque value is changed The following is a list of publications referenced in this
as a result of the ultrasonic elongation measurements, Article. Unless otherwise specified, the latest edition shall
retorque twice at the final torque value in the appropriate apply.
sequential order, followed by at least one pass in a rota-
ASME B16.5, Pipe Flanges and Flanged Fittings, NPS 1∕2
tional order, until the nuts will not turn at the target
Through NPS 24
torque. If it is not necessary to change the target
ASME B16.47, Large Diameter Steel Flanges, NPS 26
torque value, follow step (a) above.
Through NPS 60
311-4.2.8 Cutting of Bolts. Cold cutting of seized bolts ASME PCC-1, Guidelines for Pressure Boundary Bolted
and use of nut splitters is acceptable. Thermal cutting Flange Joint Assembly
methods should not be performed unless the engineering Publisher: The American Society of Mechanical Engineers
and risk analysis (see para. 311-3.1) determines that it can (ASME), Two Park Avenue, New York, NY 10016-5990
be done safely. Of particular concern are lines containing (www.asme.org)
contents that can generate a fire or release toxic materials.

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