Pop-A-Plug® Tube Plugging System for Air-Cooled Heat Exchangers

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Pop-A-Plug® Tube Plugging System for Air-Cooled Heat Exchangers

Tube leaks in ACHE units (Fin Fan coolers) can be difficult to identify and repair due to the limited access to the tubesheet through the plugsheet. Typically when leaks in the tubes are identified they are plugged by using tapered hammer-in plugs, or in higher pressure ACHE units, the plugs have to be welded in place.

In both cases, the damage frequently occurs to the tubesheet, plugsheet, and/or adjacent tubes. Pop-A-Plug Air Cooled Heat Exchanger Tube Plugging System offers significant advantages over hammer-in or welded plug applications for the following reasons:

  • Average installation time: ~2 mins./plug
  • No weld permits required
  • No expert welders required
  • Consistent and repeatable installation
  • No damage to plugsheet threads, tubesheet
    or adjacent tubes.
  • Permanent sealing solution with removability option

Related products

To see how the Pop-A-Plug Tube Plugging System bypasses the void space and plugs leaking tubes, watch the video below:


Features & Benefits

  • Unmatched Performance Under Pressure: Pop-A-Plug® CPI/Perma plugs are conservatively rated for 1,000 psi (68.9 Bar) service.
  • Reliable and Leak Tight: Properly installed, Pop-A-Plug® CPI/Perma plugs stay installed and are helium leak tight to 1x10 -10 cc/sec.
  • Quick Installation Minimizes Downtime: Pop-A-Plug® CPI/Perma plugs are simple mechanical plugs which can be installed hydraulically in minutes without damaging the tube, tubejoint or tubesheet. Installs using standard Pop-A-Plug System Ram Package or Manual Installation Tool.
  • Easy Sizing and Installation: Use PAP Tube Cleaning Brush to prepare the tube end, gauge the tube with a PAP Go / No-Go Gage, select the matching plug size and POP. Pop-A-Plug® CPI/Perma plugs may be removed using the Pop-A-Plug Removal Tool when its time to retube.
  • Broader Expansion Range: Depending on the plug size, individual Pop-A-Plug® CPI/Perma plugs can expand up to .13" (3.3 mm), reducing the number of plugs sizes required on hand.
  • Materials: Always match Pop-A-Plug® CPI/Perma plugs to the tube material. Pop-A-Plug® CPI/Perma plugs are available for immediate shipment in stainless steel 316, carbon steel and brass. Titanium and other alloys can be supplied by request - Contact factory.
  • Ordering Information: When ordering, specify tube OD and wall thickness or measured tube ID, tube material, tubesheet material if plug will be installed directly into tubesheet, maximum pressure and temperature, type of tube to tubesheet joint (rolled, welded, etc.) and condition of tubes and age of heat exchanger. Specifications subject to change.
  • Quality Assurance System: Manufactured under a Quality Assurance Program certified to ISO 9001 and several U.S. nuclear power industry standards including ANSI N45.2, NQA-1, 10CFR 50 Appendix B, and 10CFR 21.