Tube Inserts and Plugs

Widely used in electric utility power stations, industrial power plants, processing facilities and on-board ships – wherever inlet end erosion and impingement present a problem – Conco Alkaserts polyethylene plastic inserts are designed to assure lasting protection to the inlet ends of new tubes and to greatly prolong the life of worn tubes damaged by erosion and impingement.

The Conco line of industry-leading tube plugs is second to none. We offer a wide selection of tube plugs in different styles, materials and sizes to match your specific requirements. Whether you need a temporary or permanent tube plug or one that can handle vibrations, high temperatures or extreme pressures,
Conco has you covered.

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Alkaserts – Industrial Grade
Polyethylene Tube Inserts
Conco Alkaserts are inert, highly resistant to abrasion and erosion, and are unaffected by chemical treatment programs. They are dimensionally stable to 75° C, well above normal operating temperatures of steam condensers, and have a negligible effect on heat transfer. While their feathered edge design allows for the smooth flow of cooling water into the tubes, their minimum wall thickness and tapered design promotes maximum flow. Flexible enough to accommodate normal variations in tube bores, yet rigid enough for easy installation, these rugged inserts are designed to make a snug fit in the tube. Once in place, there is no danger of water seeping between the insert and tube preventing crevice corrosion.

Two Head Designs
Alkaserts are available in two head styles, bonnet and flush. While the bonnet head is designed to cover the ferrule in ferrule-type installations, the flush head is used for flush, rolled-in tubes and close-clearance tubesheet designs.

Features
• Abrasion and erosion resistant
providing lasting protection
• Negligible effect on heat transfer
• Flexible, sturdy construction
• Unaffected by chemical treatment
programs
• Dimensionally stable to 75° C
• Designed for maxim flow

Easy Installation
Alkaserts are quick to install. After inserting an Alkasert
into a tube, simply tap it home with a wooden or Micarta “persuader,” using light, sharp blows of a light mallet. That’s it, no adhesives or power tools. Compression and friction will hold the Alkasert permanently in place.

ALK-B Alkasert Polyethylene Tube Insert with bonnet head
ALK-F Alkasert Polyethylene Tube Insert with flush head

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High Confidence Tube Plugs
When you have to plug off leaking tubes in condensers and heat exchangers, the Conco patented High Confidence Tube Plugs are "Absolutely the Best" plugs you can use! Tested at pressures in excess of 70 BAR and available in 19 to 32 mm O.D. tube sizes, these tube plugs offer a separate gripping and sealing design in one plug, will not move into or out of leaking tubes, and can be used on coated or epoxied tubesheets.

Features
• Separate gripping and sealing design in one plug
• Tested to over 70 BAR under a wide range of temperature
   and vibration
• Grip made of machined serrated adjustable cleats allowing
   for positive gripping action
• Durable, expanding chloroprene cylinder provides dependable
   sealing action
• Available with metal components in titanium, stainless steel,
   brass and bronze

HC High Confidence Tube Plug

Expanding Tube Plugs
For temporary or permanent plugging of 16 to 32 mm O.D. condenser and heat exchanger tubes, Conco's line of Expanding Tube Plugs are tested to withstand a wide range of pressure, temperature and vibration conditions. The larger washer on the end of the EX-3 Tube Plug allows the plug to fit flush with the tubesheet and not be pulled into the tube by the vacuum of the unit. The EX-4 Tube Plug is designed to be placed inside the tube at exact locations, to enable leak detection tests of other tubes. These plugs can resist pressures up to
150 PSI. The EX-F Tube Plug offers a separate gripping and sealing design in one plug and seals to 28 BAR.

Features
• Installation is quick and easy
• Chloroprene cylinder material expands to seal tube
• Available with metal components in titanium, stainless steel,
brass and bronze

EX-3 Expanding Tube Plug
EX-4 Expanding Tube Plug
EX-F Expanding Tube Plug

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Fiber Tube Plugs
Easily installed for emergency and temporary
plugging of condenser and heat exchanger
tubes, the Conco Fiber Tube Plug expands
when wet to effectively seal off the tube.
These one-piece plugs will not damage tubesheets and can be used in temperatures
up to 110° C. They are available for plugging tubes
16 to 32 mm O.D.

Features
• Made of vulcanized cloth fiber rod
• Machined to fit specific tube sizes
• Only a hammer needed for quick, easy installation

FP Fiber Tube Plug

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Pin, and Pin and Collar Tube Plugs
The one-piece tapered design of the Type-1 Pin Tube Plug fits specific tube sizes. The Type-2 Pin and Collar Tube Plug features a two-piece design with a matching tapered pin and collar for a positive full-length seal. Both types of tube plugs seal at high temperaturesand isolate leaking tubes from the system, allowing continued use of the unit without major overhaul. They are available for plugging tubes 16 to 32 mm O.D. and are ideal for plugging tubesheets, where tube samples have been extracted.

Features
• Available in titanium, stainless steel, brass, and bronze
• Special materials available on request
• Can be machined to your drawing specifications

TYPE-1 Pin Tube Plug
TYPE-2 Pin and Collar Tube Plug