Vent: Had a flange weld fail on a big steam drum in Toledo last month

We were doing a hydro test on a new boiler at the plant, pressure was at 350 psi, and I heard this sharp pop. Found a hairline crack running about two inches along the root of a 6-inch flange weld. My stomach just dropped. The foreman shut it down right away. We had to drain the whole drum, which took hours, then grind out the bad section. The real kicker was the fit-up; the pipefitter left a gap that was way too big, maybe an eighth inch, and I didn't catch it before I started welding. Had to redo the whole joint with a backing ring. Ever have a test fail because of someone else's prep work? How do you guys handle that talk with the other crew?

3 comments

3 Comments

lopez.ivan2mo ago

Yeah, that eighth inch gap is a killer. Had a similar thing on a 4-inch line in Baton Rouge last year. Totally get what park.nathan means about showing the proof, sometimes they just have to see the slag or the bad gap to believe it.

thea2462mo ago

But is it really that big a deal?

park.nathan2mo ago

Remember a guy on a refinery job who swore his bevel was perfect. Hydro at 500 psi and we get a weep right at his tie-in. Turns out he used a cutting torch and left slag all in the groove. Had to have that fun chat where you show them the cold, hard proof in the failed piece.