What is the purpose of tell-tale holes in pressure vessel reinforcement pads?

1. Relieving Gas Pressure:

During welding, the intense heat can cause any trapped moisture or contaminants on the base metal (vessel wall) and the filler metal (welding rod) to vaporize. This creates pockets of gas within the weld pool. These gas pockets can weaken the weld and create imperfections. The tell-tale hole acts as a vent, allowing these gases to escape before they become trapped. This ensures a cleaner, stronger weld between the reinforcement pad and the vessel wall.

b. Pressure Testing:

Some tell-tale holes are indeed threaded. This allows for the insertion of a plug or fitting during pressure testing of the vessel. By pressurizing the area through the tell-tale hole, inspectors can check for leaks specifically around the weld between the pad and the vessel. Any leaks present will be evident through the tell-tale hole, signifying potential issues with the weld integrity. Once the pressure test is complete, the threaded hole can be plugged to maintain pressure integrity in the vessel.

c. Leak Detection (Telltale Function):

This is the core purpose of the tell-tale hole. Even after the initial pressure test and welding is complete, the hole serves as an ongoing leak detection mechanism. If corrosion or cracking starts to develop in the weld or the vessel wall beneath the pad, it will likely reach the tell-tale hole first. The presence of any leakage through the tell-tale hole indicates a potential problem and the need for further inspection. This early warning allows for repairs before a catastrophic failure of the pressure vessel.

The hole serves as a means of revealing information or signaling specific events that’s why it’s called a “tell-tale hole”.

1. Relieves Gas Pressure During Welding: When welding the reinforcement pad to the nozzle or branch of the pressure vessel, high temperatures and the welding process itself can generate gas pressure or trapped gases. This pressure needs to be relieved to prevent any potential hazards such as weld cracking or distortion. The telltale hole provides a pathway for these gases to escape during the welding process, ensuring that pressure doesn’t build up and cause problems with the weld joint or the surrounding materials.
2. Threaded for Pressure Testing: The telltale hole is often threaded, allowing it to be sealed tightly during normal vessel operation. However, during pressure testing procedures, this threaded hole can be opened to introduce pressure into the area between the reinforcement pad and the vessel. By pressurizing this space, inspectors can check for leaks around the welded joint and ensure that the connection between the reinforcement pad and the vessel is sound and able to withstand the intended operating pressure.
3. Serves as a “Telltale” for Weld Leaks: After the reinforcement pad has been welded onto the vessel, the telltale hole essentially acts as a monitoring point for the integrity of the weld joint. If the weld underlying the telltale hole develops a leak or begins to fail, this will likely be indicated by the presence of gas or liquid escaping from the hole. This serves as an early warning sign that there may be a problem with the weld, allowing maintenance personnel to take appropriate action before the issue worsens or compromises the integrity of the pressure vessel.