20.10 EPSC Learning Sheet - Plugged Heat Exchanger Tube

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Plugging Heat Exchanger Tubes

EPSC Learning Sheet December 2020

What Happened:
A technician was checking a
plug on a heat exchanger tube,
while the equipment was
heating up. Due to pressure
build-up in the tube the plug
was released from the tube
bundle with great force, killing
the technician.

Tapered plug
Hydraulic activated plug Compression fit plug
Aspects:
➢Heat exchanger tubes are regularly plugged when the tube
is leaking or has thin wall areas.
➢Tubes to be plugged should be first fully opened (cut), to
avoid pressure build-up in the tube when heating-up!
➢Define the right plug related to pressure and temperature.
➢Validate that the bore of the tube is in good condition and
that the plug is compatible with the fluids/gases used as
well as with the tube sheet material.
➢Be careful with welding that can cause tube-sheet cracking.
➢Validate leak tightness of the plug and when inspecting a
plug at a heat exchanger, stay out of the line of fire.

Plug a heat exchanger tube with care


EPSC Learning Sheets are meant to stimulate awareness and discussion on Process Safety
EPSC can not be hold liable for the use of this sheet Questions or Contact via www.EPSC.be

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