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TECHNICAL

ALERT
CONSULTING SERVICES DEPARTMENT
SUBJECT: DEFECTIVE FASANI FIRE
HYDRANT VALVES

ALERT NO.
003/02

DATE:
March 31, 2002

SUMMARY:
Hawiyah Gas Plant Inspection Unit reported failures of Fasani fire hydrant valve bonnets that
developed cracking during operation. CSD carried out a metallurgical analysis to find out the
root cause of cracking in one valve. The analysis showed unacceptable casting quality.
Further analysis of five other Fasani valves revealed similar casting defects (see attached CSD
report). These defects mainly weaken the metallurgical bonding and structural strength in the
bonnets and therefore make them very susceptible to cracking under low stress applied during
normal operation. Failure of these bonnets will hinder operation of the fire hydrant valves
during emergency needs.
Based on the above findings, Fasani (Italy) ID No. HF530001 was placed on hold.
RECOMMENDATIONS:
In order to verify the integrity of the bonnet casting, the following action shall be taken:
1. Fire hydrant valves shall be operated by using only handwheels or valve levers
supplied by the manufacturer. Valve wrenches and cheater bars must not be used since
they produce over-torque on the bonnets
2. All uninstalled Fasani fire hydrant valves shall be returned to Storehouse holding
areas. Storehouse should arrange for fully stroking and hydrotesting of these valves.
3. All installed Fasani fire hydrant valves shall be fully stroked and tested under full line
pressure.
4. Bonnets of installed and uninstalled Fasani fire hydrant valves shall be dye penetrant
tested for possible presence of any crack-like indication.
5. Defective valves shall be returned to store house for replacement.
If you have any inquiries, please call Mohammed Al-Anezi on 873-2131 or Fahad AlAkroosh on 873-3658.

__________________________
H. A. Al-Musaiid, Manager (AA)
Consulting Services Department
MAA/FAA