QUALITY BULLETIN 1/2008

FAILURE OF FABRICATED TEST BLIND FLANGE FOR HYDROSTATIC

TESTING
During the hydrostatic testing of a 40 HP Fuel Gas line, a 40diameter, 4 thickness
blind flange failed at approximately 1500 psig pressure before reaching test pressure of
1753 psig. Failure attributed to:

Failure by Contractor to meet specified quality requirements

Failure by Saudi Aramco Inspection personnel to verify requirements

The test blind flange was fabricated from plate material by the construction subcontractor (Inspector was informed this was the first time the test blind had been used.)

Following the incident, the prime contractor was instructed by SAPMT to perform an
investigation into the root cause of the failure. At the same time, Inspection instructed
corrective actions to be implemented to prevent a similar occurrence. These instructions
were again restated to the Prime and construction sub-contractor and SAPMT during the

weekly quality meeting. A preliminary report was required to be submitted to SAPMT

by close of business day.
This report was still being prepared by Contractor and the subcontractor.

An independent review by Inspection Department consisting of visual inspection of the

failed blind flange, review of the hydrostatic test package as well as several meetings
with Contractor Quality Assurance Manager and Construction QC Manager was able to
determine the following:
Blind Flange
The test flange fabricated by CCC contained no markings as to material, type and grade.
Pressure rating of 600 was written on the flange in ink marker. Further, neither

Contractor nor Construction subcontractor could provide any information regarding

welding procedures applied and welder(s) qualification. The blind flange was fitted with
two welded nipples intended for filling and venting.
Weld defects were observed on visual inspection as shown above. The flange was
fabricated during an extreme cold period the week before. The following factors may
have contributed to the failure:

The lack of pre-heat

maintaining interpass temperature control
PWHT
unsuitable welding procedures
welder qualifications
welding consumables
inadequate quality control i.e. visual and NDE inspections

Hardness tests of the weld, heat affected zone (HAZ) and base metal were requested from
Contractor. Results of hardness tests are still outstanding. It appears that failure
originated in the HAZ of the 1 nipple welded in the center of the blind flange and
propagated across the entire face of the plate to opposite bolt holes (laminar tearing type
defect.)
The failure crack depth is approximately 3 deep. Both ASME pressure vessel and piping
codes and SAES-A-004 allow for the use of fabricated flanges from plate material based
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on appropriate calculations. SAIC-A-2009 requires fabricated flanges to be supported

with appropriate engineering calculations.

Since the construction sub-contractor fabricated the blind flange in their weld
shop, calculations should have been available along with the welding procedures
and detail of the connections approved by prime contractor engineering.

The calculations were requested from both Contractor and sub-contractor but could not
be produced.

Based on actual thickness of the flange (100mm), its estimated to be at least

35% under thickness.

Hydrostatic Test Package

A hydrostatic test package is prepared for each hydrostatic test. The make-up and review
of each test package is an ongoing process involving all parties, contractor, subcontractor
and Inspection.

the hydrostatic test package was initiated by Contractor Engineering

a Pressure Testing Punchlist (Pre-Test) was prepared by subcontractor and

reviewed by contractor and PID inspector

completion of A items (work to be completed prior to hydro test) was signed

off by Contractor, subcontractor and the Saudi Aramco inspectors

Isometric/Spool control sheet was reviewed by PID inspector for completeness

Pre-Test Check List was completed by subcontractor but does not indicate review
and approval by Contractor

Item number 30 of the Contractor/Sub-contractor Pre-Test Check List (Confirm

test spades/blinds installed (as per limits)) was signed off by Sub-contractor QC

There is no provision on the Pre-Test Check List for review and sign-off by the
Saudi Aramco inspector

Test Pack Release Record (for hydro test) was initiated by subcontractor and
reviewed by prime contractor covering:
Test Pack Review Contents
Punch List Clearance (A items completed)
Isometric Control Sheet sign off
Pretest Check List

Test Pack Release Record was not signed off by the Saudi Aramco inspector

The Pre-test Check List clearly shows the sign off by the subcontractor QC inspector to
confirm that the test blind was properly installed per the test limits (item 30 on the check
list.) The Contractor/Sub-contractor hydrostatic test procedure also confirms that the
requirements of SAES-A-004 will be met. Due to the absence of calculations, this
suggests that the sign-off of item 30 was done by sub-contractor QC without actually
verifying the existence of the required calculations to verify the appropriateness of the
test flange.
Saudi Aramco Inspection Monitoring

PID inspector was present at time of hydro

The PID inspector relied on the Sub-contractor QC to verify the test flange was
of the proper rating. Saudi Aramco Checklist SAIC-A-2009 (Verification of Test
Preparation and Test Equipment for Pressure Testing), items B1 and B2 clearly
state:

Test piping, fittings and hoses are designed or have pressure rating that match or
exceed the system test pressure (G.I. 2.102, Section 4)

Paddle blinds or spectacle blinds used to isolate the test sections are of the same
class rating of the system or may be fabricated based on appropriate calculations
(SAES-A-004, Para. 7.3)
PID inspector did not verify that the installed test blind was suitable for the test
PID inspector did not utilize SAICs during reviewing and monitoring pre-test
activities

Had SA Checklists been utilized to verify test preparation and readiness then this would
have clearly identified the need to verify blind flange was supported by engineering
approved calculations.
SAIC are only used as the basis of focused assessments. At the time of this test, no
focused assessment had been done for verification of preparation of hydrostatic testing.
Corrective Actions
Project Inspection instructed Contractor/Sub-contractor to implement the following:

verify all fabricated flanges have appropriate calculation approved by Prime

Contractor engineering

all hydrostatic test equipment must be suitably identified (preferably with color
coding) to indicate the safe pressure rating

include hydrostatic test equipment list with pressure ratings and include in
hydrostatic test package
QC to verify correct test equipment is installed prior to start of test

At the time of my visit, sub-contractor was in progress of segregating and color coding
test flanges per their pressure rating/thickness. It is estimated that as many as 1000
flanges must be identified and color coded. Many test flanges were observed in the
hydrostatic test yard without any form of identification. Color coding has started on test

flanges without weld connections. Once these are complete, sub-contractor will inspect
and identify pressure ratings of flanges that have welded connections.

Note this may require the removal and re-welding of connections/attachments.

PID inspection will review that appropriate calculations have been prepared and
approved by prime contractor engineering and that welding has been performed in
accordance with suitably approved WPS and welders are qualified and will perform a
random inspection of flanges (thickness check) and color coding applied.
Recommendations
This project is in the early stages of hydrostatic testing, with over 6500 hydrostatic tests
remaining to be completed. This construction contractor as well as most others
construction contractor working on Saudi Aramco projects frequently use fabricated test
flanges for hydrostatic testing which are fabricated in their own weld shops.

All projects need to ensure to review the capability of the hydrostatic test facility
prior to start of hydrostatic testing to include all testing equipment, including test
manifolds, blind flanges, bolts, gaskets to ensure that all test equipment is
properly identified and suitable for testing
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All project inspection sections need to implement the Saudi Aramco ID SATIPs
and SAICs (Using SAIC makes the inspector more aware of SA requirements.)
ID management needs to mandate the use of the SAIC by inspectors
Revise SAES-A-004, paragraph 7.3 to include review and approval of
calculations and fabrication of test flanges by engineering/SAPMT?