That time a 2-inch weld on a steam drum in Toledo cracked during hydro

Honestly, it was my second week on a big plant job in Toledo, and we were doing the final hydro test on a new steam drum. The pressure hit 450 psi and we heard this sharp pop like a gunshot. Found a 2-inch crack right on a longitudinal seam weld that passed visual. We had to drop the pressure fast, drain the whole thing, and grind it out. The weld looked good but the base metal right next to it had a tiny slag inclusion we missed. Ended up being a 14-hour day to re-prep, re-weld, and re-test. Anyone else ever have a test go bad because of something hiding in the base metal?

3 comments

3 Comments

jamiem3018d agoMost Upvoted

Seriously, a 2-inch crack at 450 psi? That's basically a pinhole leak.

jamiem3018d agoMost Upvoted

Right? I've seen way worse hold pressure just fine.

haydenbutler17d ago

My buddy lost a finger from a "pinhole leak" that blew a chunk out of a pipe.