Rapid Leak Detection Means Less Downtime

Early tube leak testing and detection in heat exchangers, condensers, and boilers are essential to avoiding costly downtime and unnecessary damage to your equipment.

G-160 Tube Testing Tools from EST Group can quickly detect heat exchanger tube leaks using less force and increased operator safety. EST Group’s heat exchanger tube testing equipment features an ergonomic design with innovative patented grippers, offering a secure internal gripping force for reliable pressure testing, every time!

Operating Pressure

• Standard compressed air supply
• 40 to 125 PsiG (2.7 to 8.5 BarG)

Tube Size Range

• 0.49” - 1.11” (12.4mm - 28.2mm)
• with optional support tube assemblies - 0.28” - 1.81” (7.1mm - 46.0mm)

Standard Seal Material

• Neoprene

Features & Benefits

• Patented gripper design requires less operator force
• Interchangeable seal & washer sets are size-specific per tube ID
• Ergonomic design with push-button activated air injection valve
• Durable corrosion-resistant powder-coated finish
• Lightweight aluminum construction (1.9 lbs. / 0.9 kg ea.)
• Analog & Digital gauge versions available
• Fully protected gauges - analog & digital available
• Neoprene seals

G-160 Tube Testing Tool Kit Includes:

• Injection & Plugging Tools with analog gauges
• Support Tube Assemblies (GSA-1611 & GSA-1612)
• Wrench & Seal Sizing Gauge
• Impact-resistant Case

Tube Tester: Operation & Testing

What is the purpose of a leak test?

Early detection of leaking tubes in heat exchangers, boilers, and condensers is essential to avoiding costly downtime. G-160 Tube Testing Tools from EST Group rapidly detect leaks while providing a safer environment for plant personnel. Innovative patented gripper design provides increased operator safety. Operates with compressed air.

Operation Before Testing

• Step 1: The tubes to be tested should be cleaned, and any loose deposits or scale should be removed. If the tubes have not been cleaned, any foreign materials present may be ejected during the testing operation and may damage the test tools or injure the operators.
• Step 2: The operators should always wear safety glasses or a face shield when testing with the G-160 Tube Testing Tool or any type of pressure test tool.
• Step 3: If the tubes have been chemically cleaned, please check with EST Customer Service regarding the compatibility of the G-160 Tube Testing Tool Seals with the cleaning agent. Alternate seal materials are available.
• Step 4: Verify tube size to be tested.
• Step 5: Ensure the G-160 Tube Testing Tools have the correct size Seal and Washer Set (2) for the tubes being tested. The Seals and Washers are correctly sized if the OD of the Seals is 0.02" to 0.06" (0.51 mm to 1.52 mm) smaller than the actual tube ID.

Using Seals that are too small may cause any of the following:

• Premature Seal wear
• Jamming of the G-160 Tube Testing Tool in the tube
• Expulsion of the G-160 Tube Testing Tool from the tube end

Replacement Seals for the G-160 Tube Testing Tools can be procured for any tube I.D. from 0.28" to 1.81" (7.11 mm to 46.00 mm). For tube IDs larger than 1.81" (46.00 mm), contact EST.

Looking for heat exchanger tube testing equipment? Our tube leak testing tool is a component you can rely on. It’s an essential part of maintenance for your system and early detection is paramount to avoid costly downtime.  

Tube leak detected, now what? Check out our Pop-A-Plug® Tube Plugging System, a permanent mechanical solution for sealing leaking heat exchanger, condenser, and boiler tubes.

Curtiss-Wright (EST Group) has multiple options for heat exchanger tube plugs. They are used to seal leaking heat exchanger tubes to prevent damage to adjacent tubes and keep the efficiency on an aging exchanger as high as possible. Pop-A-Plug® CPI/Perma Medium Pressure Tube Plugs | Pop-A-Plug® P2 High Pressure Tube Plugs

Curtiss-Wright (EST Group) has multiple options for tube testing equipment; G-250 Vacuum Tube Testers | G-650 Vacuum Joint Testers

Further Information

Curtiss-Wright (EST Group) specializes in developing, manufacturing, and marketing highly-engineered products and repair services for shell and tube heat exchangers, condensers, coolers, and chillers. 

If you would like to contact us and speak to a sales representative, please fill out a contact form.

Repairing Tubes... for a Fraction of the Cost of Retubing

• Sleeves expand into intimate contact with the host tube
• Metallic sleeves are more easily removed than glued in plastic sleeves
• Process is faster than conventional roller expansion techniques
• Process allows the sleeve to expand and conform to the actual contours

During their operating life tubular heat exchangers are often subject to inlet tube end erosion. This erosion occurs over the first few inches of the tube end, often reducing the tube wall sufficiently enough to require the tube to be plugged. Installing a metallic tube sleeve through the eroded area of the tube end mitigates the effects of this erosion allowing the tube to be returned to service, extending the life of the heat exchanger and postponing costly retubing or bundle replacement.

Sleeving may also be implemented in a program to reclaim previously plugged tubes and increase exchanger surface area. Metallic Tube sleeves may be installed using conventional tube expanders or EST's Hydra-Loc hydraulic expansion techniques.

Why choose a metallic sleeve over plastic sleeves or inserts?

Metallic sleeves are superior to plastic sleeves or inserts for the following reasons.

1.Metallic sleeves are expanded into intimate contact with the host tube. Plastic sleeves are glued or simply pushed into the tube ends. Metallic sleeves provide better heat transfer characteristics than plastic. Metallic sleeves are considerably thinner than plastic sleeves and do not have to be removed to clean the tubes or perform ECT or IRIS tube inspections. The thinner profile of the metallic sleeves minimizes the transition between the inner edge of the sleeve and the host tube, reducing the chance of secondary tube erosion. 2.Metallic sleeves are more easily removed than glued in plastic sleeves

Features & Benefits

Hydra-Loc® Tube Sleeving System

The Hydra-Loc Tube Sleeving System hydraulically expands the sleeve into intimate contact with the tube and locks the sleeve in place. The Hydra-Loc process offers the following benefits

• Faster than conventional expansion techniques: The Hydra-Loc process is faster than conventional roller expansion techniques. Because the expansion pressure is tightly controlled the hydra-Loc process eliminates damage to the host tube and tube-to-tubesheet joints caused by over-rolling.
• Sleeve expansion conforms to actual contours: The Hydra-Loc's hydraulic expansion process allows the sleeve to expand and conform to the actual contours of the host tube end regardless of how eroded the tube has become.

When selecting sleeves choose a sleeve material that is similar to the tube material, or upgrade to a tougher alloy to reduce future erosion. The length of the sleeve should be selected so that the sleeve extends a few inches beyond the most severely damaged portion of the tube end. Standard sleeve lengths of 6", 8" and 10" are the most common, longer sleeves are available upon request. Full length tube liners are also available on request.

Hands-on Training or complete Sleeve Installation Services are available through EST Field Services.

Stabilize Weakened or Fractured Heat Exchanger Tubes

Ideal for any type of shell and tube heat exchanger from high pressure feedwater heaters to surface condensers.

Unique Pop-A-Plug anchoring system eliminates migration, ensuring fractured/deteriorated tubes are securely supported until retubing or sleeving can be performed.

Size Range: .501" to .960" ID (12.73mm to 24.38mm)

Standard Material: Stainless Steel - additional materials available upon request

Features

• Rod or cable style available
• Bullet or wedge tip configuration available
• Available in any length
• Install using standard Pop-A-Plug Ram Packages
• Anchored in position using Pop-A-Plug Technology
• Anchors available separately

Product Animations & Videos

• View Tube Stabilizer Animation
• View Installation Overview Video

Ordering Information:

When ordering, specify tube OD and wall thickness (tube ID helpful), tube material, tubesheet thickness, maximum operating pressure and temperature, length from the tubesheet face to the first tube support plate beyond the fracture, and axial clearance extending from the tube end outward (ie: length of channel head or distance to any obstruction preventing direct access to the end of the damaged tube). Specifications subject to change.

Make Boiler Repairs Faster & Easier - Reduce Downtime, Eliminate Welding, Save Money...

• Operating pressures to 1000 psi (69 Bar)
• Sizes for 1.638" to 1.823" (40.11 mm to 46.30 mm) ID Tubes
• Helium leak tight to 1x10-10 cc/sec
• Use in either water or fire tube boilers
• Ideal for HRSG's

These boiler repair plugs reliably plug boiler tubes without welding or time-consuming pre-heating.

Pop-A-Plug Boiler Plugs are made for fast, easy installation, just position the plug in place and set it with an easy-to-use hydraulic tool ram. Unique breakaway controls installation force to ensure a positive seal without damage to the tube, tube-to-tube sheet joints, providing a reliable, leak-tight seal in just minutes. Repairs go faster, and expensive downtime is substantially reduced. No welding also means no waiting for inspections.

BOILER TUBE Features & Benefits

• Unmatched Performance Under Pressure: Pop-A-Plug Boiler Tube Plugs are conservatively rated for 1000 psi (69 Bar) service @ 1000°F. Higher pressures and temperatures are available - Contact factory.
• Safe: Once installed, Pop-A-Plug Boiler Tube Plugs will not eject under pressure like hammer-in taper plugs. They are pressure rated up to 7000 PsiG (483 BarG) - tested to 1.5 safety ratio.
• Cost-Effective: Permanent solution engineered for optimal performance throughout the life cycle of equipmentSafe: Once installed Pop-A-Plug Boiler Tube Plugs will not eject under pressure like hammer-in taper plugs.
• Leak Tight Seal: Properly installed Pop-A-Plug Boiler Tube Plugs are helium leak tight to 1 x 10-10 cc/sec.
• Quick Installation Minimizes Downtime: Pop-A-Plug Boiler Tube 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. Controlled and repeatable installation force protects surrounding tubes and adjacent ligaments from damage.
• Easy Sizing and Installation: Use PAP Tube Cleaning Brush to prepare the tube end, gauge the tube with a PAP Go / No-Go Gauge, select the matching plug size and POP. Pop-A-Plug Boiler Tube Plugs may be removed when its time to retube.
• Kit: Available in kits of six plugs with a unique tube prep brush.
• Materials: Always match Pop-A-Plug Boiler tube plugs material to the tube material. Pop-A-Plug Boiler Tube Plugs are available for immediate shipment in CrMo alloy. Other alloys can be supplied by request - Contact factory. All plugs are laser etched with a lot number.
• 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.
• 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.
• Plug and tube materials to prevent galvanic interaction.
• No welding is required.

Boiler Tube Applications

Mechanical Plugs should be considered in situations where friction fit tapered plugs are not appropriate for the pressure and/or temperature of service or other mechanical/environmental conditions.

Plugging Method

Friction fit tapered plugs can be expelled during shell side pressure testing or from tubes that have not been properly vented prior to plugging, potentially resulting in serious safety concerns for surrounding personnel and equipment.

Friction Fit Boiler Tube Tapered Plugs Risks & Dangers

• Do not conform to ASME PCC-2 recommended tube plugging repair methods
• in applications above 200 PsiG (14 BarG) / 400°F (205°C)
• Lack of pressure rating resulting in unknown safety factor
• Can eject when the system is pressurized and become a lethal projectile
• Can overstress and/or damage tube joints and crack tube sheets due
• to uncontrolled installation force
• Can damage expensive epoxy coated tube sheets resulting in costly repairs
• May require welding in higher pressure services/applications
• Welded installations may make re-tubing extremely difficult and expensive

Repair Heat Exchanger Tube Leaks without Welding

When it comes to heat exchanger maintenance for shell and tube condensers and boilers, you need a tube plugging solution you can rely on.

Pop-A-Plug P2 High Pressure Tube Plugs provide a permanent mechanical tube plugging solution for leaking heat exchanger tubes without welding, eliminating potential circumferential cracking and other heat related issues associated with welding.

EST Group’s high-pressure tube plugs maximize uptime by maintaining a helium leak-tight seal that will not eject like friction fit tapered plugs. Pop-A-Plug Tube Plugs ensure stability through a ring/pin design with metallurgy matched to tube material to minimize thermal
expansion/contraction issues, and undesirable galvanic corrosion. No welding required.

Pop-A-Plug P2 High Pressure Tube Plugs provide a long-term solution that allows you to plug heat exchanger tube leaks confidently!

Pressure Rating Up to 7,000 PsiG (483 BarG) - higher pressures available upon request

Size Range 0.400” to 1.460” (10.16mm to 37.08mm) Tube I.D. -larger/smaller sizes available upon request View Size Chart

Standard Material Brass 360/464, Carbon Steel (1018 & 1045), 304/304L Stainless Steel, Copper Nickel 70/30, 316/316L Stainless Steel, Titanium – additional alloys available, contact customer service for full list

Features & Benefits

• Maximizes plant uptime by combining ease of installation and long term performance
• Engineered breakaway controls installation force preventing damage to the tube, tubesheet, and surrounding tubes
• Maintains helium leak-tight seal to 1 x 10-10 cc/sec
• Meets ASME PCC-2* recommendations and EPRI** criteria
• Accommodates Through-the-Tube Plugging applications
• Simple hydraulic installation takes only minutes
• Lowest lifecycle cost compared to alternative tube plugging methods
• Ideal for use in applications with coated tubes and tubesheets
• Large inventory available with 24/7 emergency manufacturing capability

Do you require a medium pressure tube plug? Check out our Pop-A-Plug CPI/Perma Medium Pressure Tube Plug

*Inspection and Repair of Shell and Tube Heat Exchangers, The American Society of Mechanical Engineers (ASME) PCC-2, Article 312.

** Condenser In-Leakage Guideline, Electric Power Research Institute (EPRI), Palo Alto, CA, 2000, TR-112819 Page 7.