I was running a hydro test on a 12 inch line last Tuesday and the fit slipped about a quarter inch when we hit 150 psi, water spraying everywhere before we dumped pressure. Turns out the tack welds were too light for the weight of the spool, and I had to redo the alignment with extra bracing and proper tacks. Anyone else had a test fail from something simple like that, and what do you check before you pressurize?
Sounds about right for a slip fit that got rushed. Before hitting the pump, check your fit up with a level and tape, make sure the tacks are actually sized for the spool weight, and throw a couple of braces or come-alongs on it so nothing moves once the pressure climbs. That little bit of prep saves you a whole day of cutting and redoing.