Condenser Plug Change Out

It’s time to change out your old rubber condenser plugs to Pop-A-Plugs®! Minimize Plant Downtime!


In a generating station, any forced outage is costly, especially at the peak of the generating season.  All plants that support the base load of energy need to do everything possible to maximize uptime.

As an example of the costs associated with unplanned outages, a Coal-Fired Generation Plant incurred almost $10.9 million in losses due to almost 1369 hours (over 8 weeks) of downtime due to process water contamination.  Causes for the failures were varied but one of the single largest (34%) was due to the failure of previously installed rubber condenser plugs!

These outages call for the pro-active change out of old rubber/elastomer tube plugs to the Pop-A-Plug® System for reliable, permanent and easy sealing of leaking and degraded tube plugs.

The Pop-A-Plug® is proven to provide the lowest lifecycle cost for all types of plug systems used in heat exchanger maintenance.

All Pop-A-Plug® kits are readily available with 24/7 emergency service available for any unplanned outage that may arise – anywhere. EST Group also offers outage job box kits for large plants needing a variety of plugs for their condenser systems.

How they work – the engineered solution


The Pop-A-Plug’s® unique patented pin/ring seal design is constructed of the same material as the tube metal and provides a reliable helium leak-tight seal. Installation is always a precisely controlled and repeatable process. Also important, Pop-A-Plugs are acceptable for use in coated tubes and coated tubesheets with no damage to the tubes or the sheets.
Safe installation, safe use and long life


Pop-A-Plug® CPI/Perma plugs are rated at 1000 psig (69Barg) for safe consistent plugging. And since the plug material is always matched to the tube material, thermal expansion is always consistent between the tube and the plug, eliminating the opportunity for thermally induced leaks. In addition, the installation tooling is designed for easy use to reduce fatigue and minimize the need to enter confined spaces to do the repair work, and no welding of any kind is ever required!

Choose the industry standard!!

Pop-A-Plug® has been the industry standard, in use by 85% of all Nuclear Power plants in the USA.

Recognized by:

  • ISO 9001
  • NUPIC 10CFR50 ApB; NOA-1
  • TUV
  • EPRI
  • ASME PCC-2
  • US Navy
  • CRN

For more information or to receive information on how Pop-A-Plugs® provide the best return on your repair investment contact us. We’ll send you the facts you need to know!

Condenser Plug Change Out
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