Turnarounds in Jubail and Yanbu can open hundreds or thousands of flanged joints in a few weeks. Every one of them has to be closed properly, or the start-up will be delayed by leaks. This checklist covers the bolting side of a shutdown, from early planning to start-up.
Use it alongside our wider guide to planning a plant shutdown in Saudi Arabia.
3 to 6 months before the shutdown
- Build a joint register listing every flange to be opened: tag number, line, size, class, face type, gasket, stud size and material.
- Mark critical joints (hot, high pressure, toxic, history of leaks) for extra control or bolt tensioning.
- Calculate target bolt loads and torques for each joint type, following ASME PCC-1.
- Order gaskets, studs and nuts, with some spares. Long lead items such as large spiral wound gaskets or exotic stud materials need early ordering.
- Agree the lubricant and make sure torque values match it.
- Choose the bolting contractor and check training and tool calibration.
2 to 4 weeks before
- Issue the method statement and get client approval.
- Confirm tool list and calibration certificates.
- Plan scaffolding and access for each joint.
- Identify joints that may need flange facing based on past inspection or leak history, and book a machining crew.
- Plan where cold cutting is needed for spool removal.
During the shutdown: opening joints
- Check isolation, draining, purging and permits before breaking any joint.
- Mark flange position and match-mark spools before removal.
- Use nut splitters or hydraulic spreaders on seized joints rather than heat, unless a hot work permit allows it.
- Protect open flange faces with covers.
- Bag and tag studs and nuts by joint if they will be reused.
During the shutdown: inspection
- Inspect every flange face for radial scratches, pitting and corrosion. Compare against the flange face finish guide.
- Check studs and nuts for thread damage, corrosion and necking. Replace if in doubt.
- Check alignment of the flanges before closing.
During the shutdown: closing joints
- Fit a new gasket of the correct type, size and rating.
- Lubricate threads and nut faces with the agreed product.
- Set pump pressure from the correct wrench chart.
- Tighten in passes with the agreed pattern, then check passes until nuts stop turning.
- Tag the joint and sign off the register.
- Get the client inspector’s sign-off where required.
Before start-up
- Check that every joint in the register is closed and signed off.
- Carry out hydrotesting or leak testing where required.
- Complete nitrogen purging to remove oxygen before hydrocarbons are introduced.
- Plan hot torque checks on critical joints if the procedure allows.
At start-up
- Have a bolting crew on standby for the first hours.
- Walk the unit with a leak detection plan.
- Record any leaks, the cause and the fix. Our article on why flanges leak after a shutdown will help find the cause.
After the shutdown
- Archive the joint register and records.
- Hold a short lessons-learned meeting on bolting.
- Update the register with joints that need attention next time.
Free download: print this list as a one-page form: printable shutdown bolting checklist.
Frequently asked questions
How many bolting technicians do I need for a turnaround?
It depends on the number of joints, their size and the schedule. A planner can estimate this from the joint register and typical times per joint size.
Should every joint be tensioned?
No. Tensioning is usually kept for a short list of large or critical joints. Most process flanges are torqued.
Who owns the joint register?
Usually the plant, with the bolting contractor filling in and signing each line. Agree this before the shutdown starts.
We support turnarounds with bolting, cold cutting, flange facing, nitrogen purging and hydrotest crews in Al Jubail, Yanbu, Ras Al Khair and across the Kingdom. Get in touch to plan your next shutdown.
