QUALITY BULLETIN ndash 12008

FAILURE OF FABRICATED TEST BLIND FLANGE FOR HYDROSTATIC TESTING

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

bull Failure by Contractor to meet specified quality requirements bull Failure by Saudi Aramco Inspection personnel to verify requirements

The test blind flange was fabricated from plate material by the construction sub-contractor (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

2

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 ie 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 1rdquo 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)

3

The failure crack depth is approximately 3rdquo deep Both ASME pressure vessel and piping codes and SAES-A-004 allow for the use of fabricated flanges from plate material based on appropriate calculations SAIC-A-2009 requires fabricated flanges to be supported with appropriate engineering calculations

bull 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

bull Based on actual thickness of the flange (100mm) itrsquos 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 ldquoArdquo items (work to be completed prior to hydro test) was signed off by Contractor subcontractor and the Saudi Aramco inspectors

IsometricSpool 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 ContractorSub-contractor Pre-Test Check List (Confirm test spadesblinds 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

4

Test Pack Release Record (for hydro test) was initiated by subcontractor and reviewed by prime contractor covering

Test Pack Review Contents

Punch List Clearance (ldquoArdquo items completed)

Isometric Control Sheet ndash 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 ContractorSub-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 (GI 2102 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 73)

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 ContractorSub-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

5

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 ratingthickness 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 connectionsattachments

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

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 73 to include review and approval of calculations and fabrication of test flanges by engineeringSAPMT

6

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

2

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 ie 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 1rdquo 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)

3

The failure crack depth is approximately 3rdquo deep Both ASME pressure vessel and piping codes and SAES-A-004 allow for the use of fabricated flanges from plate material based on appropriate calculations SAIC-A-2009 requires fabricated flanges to be supported with appropriate engineering calculations

bull 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

bull Based on actual thickness of the flange (100mm) itrsquos 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 ldquoArdquo items (work to be completed prior to hydro test) was signed off by Contractor subcontractor and the Saudi Aramco inspectors

IsometricSpool 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 ContractorSub-contractor Pre-Test Check List (Confirm test spadesblinds 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

4

Test Pack Release Record (for hydro test) was initiated by subcontractor and reviewed by prime contractor covering

Test Pack Review Contents

Punch List Clearance (ldquoArdquo items completed)

Isometric Control Sheet ndash 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 ContractorSub-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 (GI 2102 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 73)

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 ContractorSub-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

5

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 ratingthickness 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 connectionsattachments

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

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 73 to include review and approval of calculations and fabrication of test flanges by engineeringSAPMT

6

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 ie 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 1rdquo 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)

3

The failure crack depth is approximately 3rdquo deep Both ASME pressure vessel and piping codes and SAES-A-004 allow for the use of fabricated flanges from plate material based on appropriate calculations SAIC-A-2009 requires fabricated flanges to be supported with appropriate engineering calculations

bull 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

bull Based on actual thickness of the flange (100mm) itrsquos 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 ldquoArdquo items (work to be completed prior to hydro test) was signed off by Contractor subcontractor and the Saudi Aramco inspectors

IsometricSpool 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 ContractorSub-contractor Pre-Test Check List (Confirm test spadesblinds 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

4

Test Pack Release Record (for hydro test) was initiated by subcontractor and reviewed by prime contractor covering

Test Pack Review Contents

Punch List Clearance (ldquoArdquo items completed)

Isometric Control Sheet ndash 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 ContractorSub-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 (GI 2102 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 73)

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 ContractorSub-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

5

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 ratingthickness 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 connectionsattachments

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

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 73 to include review and approval of calculations and fabrication of test flanges by engineeringSAPMT

6

The failure crack depth is approximately 3rdquo deep Both ASME pressure vessel and piping codes and SAES-A-004 allow for the use of fabricated flanges from plate material based on appropriate calculations SAIC-A-2009 requires fabricated flanges to be supported with appropriate engineering calculations

bull 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

bull Based on actual thickness of the flange (100mm) itrsquos 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 ldquoArdquo items (work to be completed prior to hydro test) was signed off by Contractor subcontractor and the Saudi Aramco inspectors

IsometricSpool 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 ContractorSub-contractor Pre-Test Check List (Confirm test spadesblinds 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

4

Test Pack Release Record (for hydro test) was initiated by subcontractor and reviewed by prime contractor covering

Test Pack Review Contents

Punch List Clearance (ldquoArdquo items completed)

Isometric Control Sheet ndash 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 ContractorSub-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 (GI 2102 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 73)

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 ContractorSub-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

5

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 ratingthickness 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 connectionsattachments

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

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 73 to include review and approval of calculations and fabrication of test flanges by engineeringSAPMT

6

Test Pack Release Record (for hydro test) was initiated by subcontractor and reviewed by prime contractor covering

Test Pack Review Contents

Punch List Clearance (ldquoArdquo items completed)

Isometric Control Sheet ndash 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 ContractorSub-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 (GI 2102 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 73)

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 ContractorSub-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

5

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 ratingthickness 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 connectionsattachments

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

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 73 to include review and approval of calculations and fabrication of test flanges by engineeringSAPMT

6

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 ratingthickness 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 connectionsattachments

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

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 73 to include review and approval of calculations and fabrication of test flanges by engineeringSAPMT

6