Tube plugs are used to seal individual tubes in boilers and heat exchangers. They can be inserted into a leaking tube to block fluid flow temporarily or permanently. There are various types of pipe plugs available, including low and high pressure varieties. They can save time and money by avoiding the need to disassemble the entire unit for maintenance. Expandable tube plug designs use a central shaft and bolt tension to expand the body and lock the plug in place. Low pressure varieties have a flexible body that can be extended with a tool for insertion.
A tube plug is a mechanical device used to seal individual tubes in boiler and heat exchanger tube bundles. This process usually becomes necessary when a pipe begins to leak and requires isolation from the flow of water or gas through the bundle. The plug is generally inserted into the offending tube at the inlet tube sheet to block the flow of fluid therein on a temporary basis or as a permanent measure. There are numerous types of pipe plugs on the market which are usually available as low pressure and high pressure types. Most operate on an expansion seal basis and are set by turning an integral bolt or by hammering the plug into the tube opening in the case of conical varieties.
Shell and tube heat exchangers and boilers use dense assemblies of metal tubes that carry hot gases or fluids through an outer shell. To carry out any maintenance on the tube bundle, it is necessary to disassemble the entire unit and remove the bundle from the shell. Replacing a single leaking pipe deep within the bundle can be a monumental task and, fortunately, not always necessary. If the faulty hose can be identified, it can simply be blocked off so that it is isolated from the fluid flow. The loss of a single or even a pair of hoses rarely has a significant effect on beam efficiency, and this is where the humble hose cap can save thousands of dollars and many man hours and downtime.
Pipe plugs are small cylindrical devices that expand to form an effective seal in high pressure pipes. In terms of design and function, they fall into two broad categories. The former are straight wall plugs that expand to grip the walls of the pipe tightly to make a seal. The second type are tapered plugs which are typically hammered into place in the mouth of the pipe. Some pipe plug designs are even designed to be welded in place to form a permanent seal.
Expandable tube plug designs usually consist of a central shaft that is pulled back into the body of the plug by the tension of a bolt. This expands the body to lock the plug in place. Low pressure varieties often consist of a flexible body which is extended with a special tool for insertion into the tube. This effectively reduces the diameter of the cap and allows it to slide down the tube. When the tool is removed, the plug body returns to its original diameter and locks into the tube. The expansion and hammer plug types are easy enough to remove if the pipe is put back into service after repairs.
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