Spent 6 hours chasing a leak on a 40 foot stack and it was one loose plug

Last Tuesday we were doing a hydro on a 40 foot stack at the plant over in Gary and it kept weeping at the base. I figured it was a bad weld so I ground out and redid three of them, blew through two grinding wheels and most of my afternoon. Around 8pm my helper Ray shined a light on the bottom and said hey Sam, this plug looks hand tight. Sure enough one of the test plugs was only snugged down with fingers, no wrench. We tightened it and the thing held at 150 psi on the first try. Six hours of my life for one plug. Anybody else got a story where the fix was way dumber than the problem?

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