Printable Shutdown Bolting Checklist

3 to 6 months before the shutdown

• Joint register built: tag, line, size, class, face type, gasket, stud size and material
• Critical joints marked (hot, high pressure, toxic, leak history)
• Target bolt loads and torques calculated (ASME PCC-1 based)
• Gaskets, studs and nuts ordered, with spares
• Lubricant agreed and torque values matched to it
• Bolting contractor selected; training and calibration checked

2 to 4 weeks before

• Method statement issued and approved
• Tool list and calibration certificates confirmed
• Scaffolding and access planned for each joint
• Flange facing crew booked for known damaged faces
• Cold cutting planned for spool removal

Opening joints

• Isolation, draining, purging and permits checked
• Flanges and spools match-marked
• Seized joints opened with nut splitters or spreaders (no heat without hot work permit)
• Open flange faces protected with covers
• Studs and nuts bagged and tagged by joint

Inspection

• Flange faces inspected for radial scratches, pitting and corrosion
• Studs and nuts checked for thread damage, corrosion and necking
• Flange alignment checked before closing

Closing joints

• New gasket of the correct type, size and rating fitted
• Threads and nut faces lubricated with the agreed product
• Pump pressure set from the correct wrench chart
• Tightened in passes, then check passes until nuts stop turning
• Joint tagged and register signed off
• Client inspector sign-off obtained where required

Before and at start-up

• Every joint in the register closed and signed off
• Hydrotest or leak test completed where required
• Nitrogen purge completed before hydrocarbons are introduced
• Hot torque checks planned on critical joints (if procedure allows)
• Bolting crew on standby for start-up
• Leaks recorded with cause and fix

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