Pop-A-Plug P2 High Pressure Tube Plugs

EST Pop-A-Plug P2 high pressure tube plugs provide a mechanical sealing option for leaking heat exchanger tubes without welding the plug in place.

Published rating: up to 7,000 psig (483 barg), subject to the selected application.
Published tube ID range: 0.400–1.460 in. (10.16–37.08 mm).
Match the plug alloy, prepared bore and installation tooling.

Pop-A-Plug P2 tube plugs use an engineered ring-and-pin design to seal prepared heat exchanger tubes. Controlled installation force expands the plug into the tube. This mechanical approach avoids applying welding heat to install the plug and supports maintenance where tube alloy, operating conditions and access require an engineered plugging solution.

High pressure tube plug selection

The published P2 family rating is up to 7,000 psig (483 barg), with tube ID sizes from 0.400–1.460 in. (10.16–37.08 mm). Select the exact plug from its permitted expansion range; the complete family range is not the adjustment range of one part.

Information needed to size P2 tube plugs

Send the following details so Justram can confirm the correct P2 plug size and material:

Tube outside diameter (OD)
Tube wall thickness or gauge (BWG), stating whether it is the minimum wall or the average wall
Maximum pressure the plugged tube must hold, and whether it is operating or test pressure
Tube-to-tubesheet joint: rolled, welded, or rolled and welded
Tube and tubesheet materials, service temperature and the number of plugs required

Higher pressures or sizes outside the standard range require a separately confirmed configuration.

Alloy and service compatibility

Standard material choices include brass, carbon steel, 304/316 stainless steel, 70/30 copper-nickel and titanium. Other alloy options include duplex and super duplex stainless steels, nickel alloys and chrome-moly grades, subject to size and availability.

Closely matching plug and tube metallurgy is part of managing thermal expansion and galvanic compatibility. Request the material grade and any traceability or project documentation with the quotation. The selected repair method must meet the facility’s applicable inspection and engineering requirements.

Installation tooling and ram rental

P2 plugs require compatible installation tooling and the specified tube preparation. Justram offers Pop-A-Plug installation ram package rental; confirm the correct ram, pull rods, accessories and availability for the selected plug sizes.

The manufacturer lists standard P2 kits with ten plugs, a tube preparation brush and a Go/No-Go gauge. Confirm the kit contents and separately required installation equipment before ordering. Use the matching installation procedure; removal for retubing requires the appropriate removal tooling.

Compare tube plugging options

CPI/Perma medium pressure plugs offer a different expansion range and a published rating up to 1,000 psig. Torq N Seal mechanical tube plugs use a different torque-controlled installation method. Application suitability and tooling should be compared for the actual tube and service.