How To Design Plug For Tube Heat Exchanger

They got em here...

http://www.tubeplug.com/

In the latter days of steam locomotives, leaking boiler tubes would be "fixed" by filling them up with cement.

Never thought of that cement approach???? I've made plenty of brass tapered plugs and also purchased loads from McMaster Carr. But in a big pinch I suppose a cement or even a resin would work out fine.

On that note I could see using a resin like chock fast orange or something similar

Normally tube plug design is given by the heat exchanger manufacturer. Plug should be such that if tube get snap beyond tube sheet, it shall be retained in the same position and should not cause damage to other near by tubes.

Just have a look at what Solar Eagle has provided, they have very good small diameter plugs in that link that are even easily installed with a crescent wrench.

GA SE

But oranje24, this is not rocket science and a typical plug design as seen in the Solar Eagle link for boiler plugs works just fine in smaller diameters as well, it should be a very slight taper to ensure it applies pressure to the tube sheet and not just the tube end itself. Its really just common sense.

We plug leaking tube by pushing and hammering a tappered plug made of copper about 30 mm long and average dia same as tube ID and bigger dia is 1 mm more than it. After hammering about 5 mm length is produding outside. It works successfully.