Wrong fitting size for 5 years, a leaky flange pointed it out

So I've been doing boiler work around Cleveland for a while now, and I always grabbed what I thought was a standard 2-inch fitting for a certain job. Last Tuesday I had a pressure test fail on a new install because of a weep at the flange, and when I pulled it apart I saw the gasket was sitting crooked. Turns out I'd been using a 2.5 inch reducer with the wrong bore the whole time, just because the outside threads looked the same. The old foreman at my first shop never checked the actual ID, he just eyeballed it and said it's fine. Anyone else have a moment where a tiny leak or crack revealed they'd been using the wrong part for years?

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leo_price11d ago

Man, that's like how half the stuff in my house is held together by whatever I grabbed first, not what actually fits.