Boiler Tube Plugs

Before welding, it is necessary for the technician to obtain the appropriate material certification for the plugs. This certification confirms the use of the correct plug type and allows for traceability should any issues arise. Heat lot numbers are available for SA-105 plugs, providing additional documentation that verifies the plugs’ integrity and quality.

Prior to inserting the plug into the defective tube, it is crucial to pierce the tube at both the top and bottom to prevent air from being trapped inside after plugging.

It is very important to allow water to flow through the tube to prevent internal pressurization.

Care must be taken to complete the welding according to the appropriate procedure. Neglecting proper procedures can result in damage to the tube sheet, which can lead to increased costs over time. Moreover, proper welding ensures that the plug is sealed as effectively as possible, which is particularly critical when the tube is more corroded. A well-executed weld can create a tight seal, preventing any leaks or dislodgement of the plug.

The optimal tool for this task is the One Revolution Internal Tube Cutter. As shown, this tool is manually operated using the socket and T-bar method. As the tool is rotated, the cutter extends from the tool and makes a complete cut through the tube wall. A short cut of approximately 20mm at both ends is sufficient. It is advisable to make the cuts at the top and bottom of the tube to ensure no air is trapped.