Pop-A-Plug CPI Perma Tube Plugs
EST Pop-A-Plug CPI/Perma mechanical tube plugs seal leaking heat exchanger and condenser tubes using controlled installation tooling.
- Published pressure rating: up to 1,000 psig (68.9 barg).
- Published tube ID range: 0.472–2.067 in. (11.99–52.5 mm).
- Select the plug size, alloy and tooling for the actual tube and service conditions.
Pop-A-Plug CPI/Perma tube plugs provide a mechanical method of taking leaking heat exchanger or condenser tubes out of service. The system uses controlled installation force to expand the plug into the prepared tube bore. Plug selection and tube preparation are matched to the material and application.
Pressure and bore selection
The published CPI/Perma rating is up to 1,000 psig (68.9 barg), with standard listed tube ID coverage from 0.472–2.067 in. (11.99–52.5 mm). Each plug covers its own expansion range. Confirm the prepared bore, wall thickness, temperature and operating conditions before specifying a part.
For higher-pressure requirements, compare Pop-A-Plug P2 high pressure tube plugs. A different family or special configuration requires its own selection and installation review.
Match the alloy to the tube and service
Published standard materials include brass, carbon steel, 304/316 stainless steel, 70/30 copper-nickel and titanium. Other alloys include duplex and super duplex stainless steels, nickel alloys, zirconium and chrome-moly grades, subject to the selected size and configuration.
Provide tube and tubesheet materials, fluid exposure and operating temperature. Material matching helps address thermal expansion and galvanic compatibility, but suitability must be assessed for the actual service. Identify any material traceability or project documentation requirements with the enquiry.
Installation system and maintenance planning
Specify the matching installation tool, pull rod, accessories and sizing gauge with the plugs. The manufacturer describes standard kits containing ten plugs and one Go/No-Go gauge; confirm the exact kit contents and tooling supplied in the quotation. Through-the-tube applications require the corresponding procedure and access review.
CPI/Perma plugs can be removed using the appropriate removal tooling when retubing is required. Installation and removal should follow the manufacturer’s instructions for the selected plug material, size and tube condition.
Technical documents and quotation
CPI/Perma technical brief — MK0004 (PDF). Access installation and tooling instructions in the Pop-A-Plug documentation library.
Send the tube OD, wall thickness, measured/prepared ID, tube and tubesheet alloys, operating pressure and temperature, access details and quantity. Request a CPI/Perma tube plug quotation.
