TIL why my tube rolling kept leaking, and it took a guy in Beaumont to point it out
I was helping retube a small firetube boiler at a shop outside Beaumont last month and every rolled joint on my first pass leaked at the test. An old hand watched me for about 5 minutes and asked how far past the tubesheet I was running the roller. Turns out I was pushing in almost 3/4 inch when he said the rule is to stay within the tube wall thickness plus about 1/8 inch, so roughly 1/2 inch on this job. He also had me slow the rpm down and do two lighter passes instead of one heavy one. We re-rolled 14 joints that afternoon and only had one seeping. Now I keep a piece of tape on the roller as a depth marker. Has anyone else had a lead hand fix a rolling habit like that on the spot?