PRODUCT INFORMATION GUIDE
Hydrostatic Testing and Isolation
Heat Exchanger Testing and Plugging
Heat Exchanger Manufacturing and Repair
EST Heat Exchanger
EST Field Services
Hydrostatic Test & Isolation
Hydrostatic Test Pumps
Heat Exchanger Tube Plugs
EST GROUP Heat Exchanger Plug Installation
& Removal Tools
A global manufacturer and designer of pipe and tube pressure
testing and plugging equipment, located in Hatfield, PA. Since 1968,
Heat Exchanger Tube Testers
EST Group has specialized in the development, manufacturing,
and marketing of tools and systems that greatly simplify the 15
Plumber’s & Specialty Tools
maintenance of shell and tube heat exchangers and that speed-up
the in-service inspection of pipe, pipelines, piping systems, and
pressure vessels. Our plugging systems have saved millions of
dollars in maintenance and downtime.
In 2009, EST Group was acquired by Curtiss-Wright Corporation,
under the Flow Control segment. We serve the power generation,
refining, petrochemical, fine chemical and pharmaceutical industries
worldwide. EST Group’s divisions include EST Field Services and
EST Heat Exchanger.
Quality Assurance System:
Manufactured under QA program
certified to ISO-9001.
Can be supplied under ANSI N45.2,
10CFR50 Appendix B.
EST HEAT EXCHANGER
EST Heat Exchanger’s Baton Rouge, Louisiana, manufacturing facility
fabricates and repairs fixed tube sheet, floating head, and U-tube heat
exchangers in accordance with ASME Section VIII Division 1 Part UHX. In
addition, we manufacture double pipe (conventional and high pressure) and
air cooled heat exchangers. Need a spare? We also produce replacement
bundles for your existing exchangers.
If you need to get back on line fast, we’ve got the solution. We provide
retubing, weld overlay, and machining services. We have the equipment,
experience, and staff to meet the demands of even the tightest turnaround
schedule. As holders of ASME “U”, NBIC “R” and “NB” stamps, EST Heat
Exchanger offers expert pressure vessel design, fabrication, and repair to
State of the art vertical machining center.
Better throughput translates into increased productivity, shorter lead times,
and reduced man-hours. The machining center is ideally suited for all
drilling and milling operations on tube sheets and tube support plates in
thicknesses up to 10 inches. The large 96 x 93 inch bed allows finishing of
tube sheets as large as 7 feet in diameter with one set up.
EST FIELD SERVICES
EST Field Services provides a complete range of on-site services for your
shell and tube heat exchangers, condensers and oil coolers. Our trained
service technicians have the experience and know-how to handle even the
most demanding jobs, safely, competently and on-time. Strategically located
in Baytown, Texas, Baton Rouge, Louisiana, and Hatfield, Pennsylvania,
we can quickly respond and meet even the tightest repair schedules. Join
our growing list of satisfied customers in the nuclear and fossil power
generation, chemical, petrochemical, oil refining, pharmaceutical, industrial
gas, shipbuilding, and boiler manufacturing industries.
• Tube Inspection and Testing
• Pipe and Pressure Vessel Inspection and Testing
• Tube Cleaning
• Tube Sleeving, Lining, and Plugging
• Tube Removal
“R” Stamp Field Welding Repairs
• Nozzle Changes
• Support Pads
• Shell Repair
• Tubesheet Repair
• Channelhead and Dome Overlays
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HYDROSTATIC TEST & ISOLATION PLUGS
High pressure pipe testing is safer than ever before. Unlike other plugs that can loosen and eject under high
pressure, even becoming dangerous projectiles, the GripTight™ high pressure test plug actually uses test pressure
to grip and seal more securely against the pipe’s inner diameter. The greater the pressure, the greater the grip! The
result is a quicker installation, better sealing, and all around safer testing. Operating pressures to 13,900 psi (960
Bar), depending on plug size. Sizes from 0.93” to 8.53” (23.6mm to 216.7mm) in stock. Larger sizes through 42”
(1066.8mm) available. For smaller sizes, see the SQ2 test plugs.
Double Block and Bleed
The DBB Plugs allow an operator to positively isolate and monitor potentially explosive vapors during “hot work”,
then effectively hydrotest the new weld connection with one easy to use tool. The aluminum/steel construction
makes the tool highly portable, and easy to position. The volume of water required for testing is so small that testing
can be accomplished using a simple hand pump. This greatly facilitates testing in remote areas of the facility. ¾”
to 24” pipe sizes. Schedule 40, 80 and STD. Other sizes available. Pressure rated to 2,250 psi (155.1 Bar). Back
pressure rated to 10 psi (0.7 Bar).
EST Group offers safety gags and pipe restraints for test plugs. Safety gags indicate
excessive movement of GripTight™ high pressure test plugs during hydro testing. Pipe
KNOW restraints clamp to the O.D. of a tube or pipe to act as secondary plug restraints during a
pressure test. Contact customer service for more information.
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HYDROSTATIC TEST & ISOLATION PLUGS
Reverse Pressure GripTight™
The solution to the growing concern over inadequate longitudinal stress when testing welded flange connections.
By isolating the test area between a test flange and our RPGT plug, the weld joint is subjected to both radial and
longitudinal stresses during hydrostatic testing. Operating pressures to 2,250 psi. Available in sizes 2” to 12” - larger
sizes available. 4” and larger plugs provide up to 0.5” (12.7mm) pipe clearance.
High Lift Flange Weld
The High Lift Flange Weld Test Plug lets you monitor downstream conditions, isolate and purge the weld area,
perform the weld, and hydro test the weld joint using only one tool. No blind flanging upstream, no vacuum truck
for evacuating the line, and no X-raying. Each test requires a minimum amount of water, and there is no need to
fill the entire line. You will use less water,and minimize your environmental liabilities. Operating pressures to ANSI
B16.5 requirements. Pipe sizes from ¾” to 24” (DN20 to DN600). Larger sizes available. Flange classes 150 to 600
lb. Higher classes available. All flange styles. High Lift seal design provides improved seal-to-pipe clearance.
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HYDROSTATIC TEST & ISOLATION PLUGS
High pressure testing is faster and easier, thanks to the SQ2 high pressure test plugs.
Twin cone design allows our SQ2 Plugs to be easily installed and removed without
causing extensive damage to the pipe wall surface. Operating pressures to 6,500 psi
(446 Bar). Sizes from 0.48” to 0.92” (12.1mm to 23.4mm). Shown with optional pipe
Socket Weld (SQS)
SQS test plugs are designed to facilitate testing socket weld fittings and couplings.
During installation the grippers expand within the socket holding the plug in position
while the seal element expands and seals off the bore of the fitting. Designed for ASTM
A105 3000 LB carbon steel socket weld fittings. Sizes to fit ½” through 2” fittings,
operating pressures to 5,000 psi, depending on plug size. Larger sizes available.
Auto GripTight™ Testing System (GTA)
The AutoGT testing system speeds the plug installation and testing process by
replacing the compression nut with a compact hydraulic cylinder. Ideal for automated
testing applications in pipe or tubing I.D.’s ranging from 0.50” to 4.34” (12.7mm to
110.2mm) and operating pressures to 6,500 psi (446 Bar). Contact customer service
and let us help you design a system.
The Bolt Type medium pressure test plugs are designed for simple and reliable testing
of pipe and tubing, without the tube wall damage associated with other test plugs.
That’s because our Bolt Type plugs feature a neoprene seal - the only part of the plug
that comes in contact with the tube I.D. To use, simply install into the open end of the
pipe or tube and tighten the large compression nut to expand the seal element. Then
begin testing. Operating pressures to 250 psi (17.2 Bar), depending on plug size. Sizes
for 0.28” to 10½” (7.11mm to 266.7mm).
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HYDROSTATIC TEST & ISOLATION PLUGS
No more having to square and round pipe ends to fuse on end caps. Just slip the
GripTight™ PE plugs in the open ends of a section of pipe, tighten and begin testing.
Testing can be performed on installed pipe or while it’s still on the spool. Available
in 2”, 3”, 4”, 6”, and 8” pipe sizes (DN50 to DN200). Plug sizes to cover 9 to 17 SDR
applications in either HDPE or MDPE pipe - other sizes available. Patented dual seal
design. Conservatively rated to 150% of maximum operating pressure required under
49 CFR 192.513.
The Economy Low Pressure Test Plugs are designed for simple and reliable testing of
pipe and tubing, without the tube wall damage associated with other test plugs. That’s
because our Economy plugs features a neoprene seal - the only part of the plug that
comes in contact with the tube I.D. Simply install the Economy Test Plug into the open
end of a pipe and tube tighten the plug (2” to 4” sizes use a hex nut) to expand the
seal. Begin pressure testing. Operating pressures to 35 psi (2.4 Bar), depending on
plug size. Sizes for 3/8” to 4” (9.53mm to 89.2mm).
The O.D. GripTight™ uses EST Group’s proven self-gripping, self-sealing feature in
combination with a dual seal mechanism to provide unparalleled speed and safety in
hydro-testing. GripTight design grips and seals along the pipe O.D. Since pipe O.D.’s
are constant, one O.D. plug often replaces several different sizes of I.D. sealing plugs
providing an economic advantage and lower inventory. Operating pressures to 5,000
psi (343 Bar). ¼” to 3” ANSI pipe sizes. ½” to 3½” tube sizes. Metric pipe and tubing
Threaded Pipe Stoppers
Ported hand tightened stoppers provide a face seal on NPT threaded connections
without the use of sealants or hand tools. NPT size ranges from 1/8” to 4”. Operating
pressure ratings vary by size and range, from 500 to 5,000 psi (34.3 to 344.7 Bar).
DID YOU EST Field Services offers piping system and pressure vessel hydrostatic testing and
inspection. EST Field Services also provides on-site training courses for all EST Group
products. Contact EST Field Services for more information.
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HYDROSTATIC TEST & ISOLATION PLUGS
Medium Pressure Inflate-A-Plug
A medium pressure ported test plug, ideal for testing and plugging sewer lines,
storm drains, pipe lines, and cooling water intakes. Features an aluminum body with
an inflatable seal. Nominal pipe sizes from 4” to 36” (DN 100 to DN 900). Medium
pressure rating to 100 psi (6.9 Bar).
Low and Medium Pressure Rim Bolt
Low and medium pressure ported test plugs. Typical uses include vent plug, purge
plug, or nite caps. Sizes from 8” to 36” (DN 200 to DN 900). Operating pressures to 70
psi (4.8 Bar) vary depending upon size and style.
A low pressure, low cost ported test plug. Nominal pipe sizes from 2” to12” (DN 40 to
DN 600). Operating pressures to 10 psi (0.7 Bar), depending on plug size.
The Tri-Light Isolation Plug allows you to quickly isolate open pipe ends while
performing hot work. The triple seal design creates three separate contact points
while sealing against the pipe wall, affording your pipe crew a considerably safer work
environment. Speeds pipe modifications and repairs. One man installation. Vented
plug design allows monitoring upstream conditions.
Inflatable Stoppers: Round, Cylindrical, and Pillow
Used to seal gas lines, water lines, purge and containment. Available in sizes from 2”
to 72” (DN 50 to DN 2400), depending on model stopper selected. Operating pressure
ratings from 69 to 1 psi (4.8 to 0.07 Bar), depending on size and style selected.
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? EST Group offers pipe caps and vents for all test plug models. Caps allow ported test plug
designs to act as blind plugs. Vents help vent air or gases through plugs as the vessel or
piping system is being filled for testing. Contact customer service for more information.
HYDROSTATIC TEST PUMPS
A compact portable air driven diaphragm style pump. Ideal for hydro testing heat
exchanger tubes, pipe and pressure vessels in the field or in the shop. Available in a
number of output pressures ranging from 2,500 to 10,000 psi (172.4 to 689.5 Bar).
All stainless steel water side. Easy to read 4” (100 mm) diameter pressure gauge.
Completely enclosed in a lockable aluminum tool box. Supplied with 10ft (3.1 m) high
pressure hose with quick couplings for air and water inlet connections.
A fully self contained and portable hand pump for testing tubes, pipes, or various
pressure vessels. It is integrated into a 5 gallon attached resevoir which is easily
refilled. The hand operated handle keeps it independent from a supplied compressed
air source. With the turn of a knob, the pressure output can be adjusted to either
1,000 psi, 2,000 psi, or 3,000 psi for the appropriate application. It has a silicone-filled
gauge for all weather use and minimal moving parts for durability and longevity. High
pressure bleed valve and hose with swivel fitting included.
Blue Max 3
A larger air driven diaphragm style pump mounted on wheels for mobility. Suitable for
all hydrostatic testing applications. Available in a number of output pressures ranging
from 1,000 to 10,000 psi (69 to 686.3 Bar). Higher pressures available. The Blue Max
pumps features include: All stainless steel high pressure side. Easy to read 4” diameter
pressure gauge. Self-contained in tool box that has storage for hose, fittings and
plugs. Supplied with mating quick connect couplings for air inlet, water inlet and high
pressure outlet connections.
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HEAT EXCHANGER TUBE PLUGS
Pop-A-Plug® II (P2)
A proven long-term performer in fossil and nuclear stations, the P2 features patented internally serrated rings
designed to maintain a leak tight seal under extreme thermal and pressure cycling. P2 tube plugging system reduces
downtime, eliminates welding and explosives, and will not damage your tubes, tubejoints or tubesheet. Pressures to
7,000 psi (480 Bar). Sizes 0.400” to 1.46” (10.16mm to 37.08mm) tube I.D.. Proven helium leak tight to 1 x 10 -11 cc/
sec. Installs quickly and easily, unique breakaway prevents damage. Larger and smaller sizes available. Removable
for retubing. Meets ANSI N45.2, 10CFR50 App B, 10CFR21, and certified to ISO9001.
Perma Plugs™ use proven Pop-A-Plug® technology to provide a leak tight seal while eliminating collateral damage
to tubejoints and tubesheets. Once installed Perma Plugs stay installed until its time to retube. Operating pressures
to 300 psi (21 Bar). Sizes for 5/8” to 1½” (15.88mm to 31.75mm) tube sizes. Helium leak tight to 1 x 10-11 cc/sec.
Removable for retubing. Designed for the rigors of power plant condensers, Perma Plugs provide a permanent leak
tight seal so you can set them and forget them. No more leaking or lost plugs. Controlled installation force eliminates
damage to tube joints and epoxy coated tube sheet. Meets ANSI N45.2, 10CFR50 App B, 10CFR21, and certified to
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EST Group offers Go/NoGo gauges in a veriety of sizes to determine the correct plug size
needed. Contact customer service for more information.
HEAT EXCHANGER TUBE PLUGS
Designed to meet the rigors of the Chemical Process Industries, CPI Pop-A-Plugs®
are resistant to thermal cycling and able to provide a seal that is helium leak tight. CPI
Pop-A-Plugs install using controlled force. This protects against damage to tubesheet
ligaments and adjacent tubesheet joints, extending the life of your heat exchanger and
reducing total operating cost. Operating pressures to 700 psi (48 Bar). Tube sizes for
0.472” to 2.067” (11.99mm to 52.50mm) ID tubes. Helium leak tight to 1 x 10-11 cc/
sec. Larger sizes available. Removable for retubing. Meets ANSI N45.2, 10CFR50 App
B, 10CFR21, and certified to ISO9001.
Pop-A-Plug® Boiler Tube Plugs
Reliably plug boiler tubes without welding, time consuming preheating and post weld
stress relieving on the weld inspections that go with it. The unique Breakaway controls
installation force to ensure a positive seal without damage to tube, tube-to-tubesheet
joints. Operating pressures to 1000 psi (69 Bar). Sizes for 1.579” to 1.823” (40.11 mm
to 46.30 mm) ID tubes. Larger sizes available on request. Helium leak tight to 1 x 10-
11 cc/sec. Use in either water or fire tube boilers. Ideal for HRSG’s. Meets ANSI N45.2,
10CFR50 App B, 10CFR21, and certified to ISO9001.
Vibra Proof Condenser Plugs
A metal, expandable elastomer condenser plug. Available for tube ID ranges from
0.28” to 1.28” (7.1mm to 32.5mm). Maximum pressure rating is 150 psi (10.3 Bar).
Brass or stainless steel with elastomers of neoprene, silicone, or fluoroelastomer.
Pop-A-Plug® Tube Stabilizers
Effectively stabilizes weakened or fractured heat exchanger tubes. Ideal for any type of
tubular heat exchanger from high pressure feedwater heaters to surface condensers.
Sizes to fit tubes ranging from 0.50” to 0.96” I.D. (12.73mm to 24.38mm). Available in
either rod or cable type configuration. Available in any length.
DID YOU Unique to EST Group’s Pop-A-Plug® system, the Through-The-Tube Plugging™
procedure allows a tube plug to be passed the length of a straight through tube
heat exchanger without having to remove the bundle or far end cover. Contact
customer service for more information.
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INSTALLATION AND REMOVAL TOOLS
Pop-A-Plug® System Ram Packages
There is no better way to install Pop-A-Plugs® than with our hydraulic installation
equipment. Our Small and Large Ram Packages are designed to hydraulically install
Pop-A-Plugs® in seconds. The rams are compact, lightweight and easy to use. Installs
Pop-A-Plug® Tube Plugs quickly, safely and easily. Ram packages include hydraulic
ram, pump, pressure gauge, high pressure hose, and a metal storage tool box.
Pull Rod Assemblies
EST Group stocks a complete complement of Pull Rod assemblies, Channel Head
assemblies and extensions for both near end and Through-The-Tube Plugging™
Close Quarters Ram (CQ Ram)
The Close Quarters Ram lets you install Pop-A-Plugs® even when there’s only minimal
clearance around the tube end. Ideal for tubes in the outermost row of tubes of a
closed head feedwater heaters, or in tubes adjacent to a pass partition or divider
Pop-A-Plug® Manual Installation Tool (MIT)
Providing fast, reliable installation in situations where no air or electricity are available.
Each MIT comes complete with Pull Rod and Positioner to install the size and style
Pop-A-Plug® identified in the tool’s model number. The same MIT body will accept
all pull rods and positioners for P2’s up to 1.160” and CPI/Perma Plugs up to 1.149”.
The MIT can be used with manual wrenches or sockets, as well as with electric or
pneumatic impact wrenches.
Tube preparation is vital to successful tube plugging. EST Group’s full complement
of unique tube preparation brushes deliver fast, consistant tube preparation. Tube
preparation brushes size the hole and make it round, quickly remove leak causing
surface defects, and provide a roughened surface, improving the plug’s pressure
holding capability and leak tight integrity.
Pop-A-Plug® Removal Tool (PRT)
Quickly and easily remove installed Pop-A-Plugs® with the Removal Tool. A dual
function tool, the PRT features a nose piece that threads into the pin of an installed
plug, enabling you to drive the pin from the ring. The tool retains the pin while a
serrated spear grabs the ring’s ID. An integral slide hammer then lets you pull out the
ring and pin in one operation.
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HEAT EXCHANGER TUBE TESTERS
G-150 / G-150A Tube Testers
Designed to pneumatically test individual heat exchanger tubes for leaks. Either the entire tube bundle or an isolated
number of tubes in the bundle can be tested using standard plant air supplies. Interchangeable seal and washer
sets allow the G-150’s to test tube I.D. sizes from 0.280” to 1.230” (7.1mm to 31.2mm) I.D. The larger G-150A
Testing Guns will operate on tube I.D. sizes to 2.5” (63.5mm) I.D. G-150 Tube Testing Gun Set includes one G-150
Air Injection Gun and one G-150 Tube Plugging Gun. The G-150 Air Injection Gun and G-150 Plugging Guns weigh
less than 2.4 lbs. each. Replacement seal and washer sets, channel head extensions, and digital gauges are also
G-250 Vacuum Tube Tester
Designed to quickly seal off and evacuate individual heat exchanger tubes to test the tube for leakage. The G-250
set is supplied with a vacuum test gun, plugging tool, and two sizes of interchangeable conical seal and washer
sets in a compact toolbox. The seal and washer sets allow the G-250 to be utilized to test heat exchanger tube I.D.s
ranging from 0.28” to 1.45” (7.1mm to 36.8mm) I.D. The G-250 gun is machined from high strength aluminum alloy
reducing the fatigue associated with heavier testing equipment. Each G-250 set weighs less than 2.5 lbs (1.1kg).
Optional seal set is available to test tubes to 2.5” (63.5mm). Replacement seal and washer sets, channel head
extensions, and digital gauges are also available.
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HEAT EXCHANGER TUBE TESTERS
G-450 Tube Tester
Designed to allow testing of straight tube heat exchangers when access is restricted to one end of the tube. Ideal for
testing tubes in floating head HX applications with the tube bundles in place. The G-450 utilizes standard plant air
supplies.Interchangeable support rod & tube extension assemblies, and seal and washer sets allow the G-450 to test
tube I.D. sizes from 0.5” to 1.23” (12.7mm to 31.2mm) I.D. Digital gauges are also available.
G-650 Vacuum Tube Joint Tester
Designed to quickly test expanded tube-to-tubesheet joints for leakage. Ideal for heat exchanger manufacturers
or companies performing retubing operations. The G-650 Gun seals the tube I.D. and the tubesheet face, then
evacuates the tube end at the joint. A loss of vacuum indicates a leaky tube joint. The G-650 Gun operates on
standard plant air supplies. A highly efficient venturi creates 21 to 24 in-Hg (707 to 808 mBar) vacuum on an inlet
air supply of 100 psi (6.8 Bar) and 10 SCFM. Interchangeable manifolds, and seal and washer sets allow the G-650
to test tube-to-tubesheet joints on 3/8” O.D. to 1¼” (9.5mm to 31.8mm) O.D. tubes I.D. sizes from 0.280” to 1.21”
(7.1mm to 30.7mm) I.D. The larger G-650A Joint Testing Gun will accommodate tube I.D. sizes from 1.17” to 2.46”
(29.7mm to 62.8mm). The G-650 Guns are not suitable for testing excessively belled / flared tube ends, or tubes
with welded tube-to-tubesheet joints. Digital gauges are also available.
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PLUMBER’S & SPECIALTY TOOLS
The DutchFinger® Tools: O-Series, TBD Series, FPT Series
The O Series is used to repair or replace a full port ball or gate valve while under
pressure. Pipe sizes range from ½” to 4” (DN 15 to DN 100). Pressure ratings 200 to
15 psi (13.8 to 1 Bar). The TBD Series is used to repair full port ball or gate valves in
piping systems under medium pressure. Incorporates a seal and a gripper to lock itself
into position. Pipe sizes range from 1” to 4”. Pressure ratings are from 600 to 250 psi
(41.4 to 17.2 Bar), depending on size. The FPT Series is used to repair and replace
full port ball or gate valves on tanks and headers. This is an ideal tool to replace
leaking tank bottom valves. Available in size ranges from 2” to 10” (DN 50 to DN 250).
Pressure ratings are from 600 to 250 psi, (41.4 to 17.2 Bar), depending on size.
DutchFinger® Watergate Tools
Prized by plumbers for simplifying soldering copper pipe. Available in kit form for ½”
to 1”, 1¼ to 2”, and ½” to 3” pipe sizes. Individual tools also available up to 4”.
H-Series Hot Tap Kit
Allows manual or power tapping of existing lines and extends service without
shutting off existing pressure. Available in individual tools or a variety of kits from ½”
to 6” (DN 15 to DN 150) line size. Max pressure for all tools is 150 psi (10.3 Bar).
D-Series Tapping Tools
Ideal for decontamination and disposal (D&D) work, D-Series Tapping Tools facilitate
tapping, sampling and draining the contents of pipe and pressure vessels. The
large ¾” NPT outlet on the tools’ body provides sampling and drainage port. Simple
bolt-on installation – no welding or pyrotechnics are needed. All stainless steel
construction with titanium nitride coated drill bit and GoreTex® gaskets. Available
for pipe sizes from ¼” through 3” at working pressures to 285 psi. Tubing sizes and
larger pipe sizes are available.
800.355.7044 | 15
EST Group EST Heat Exchanger EST Field Services and Rental
Curtiss-Wright Flow Control 1056 Neosho Avenue 3201 N. Highway 146
2701 Township Line Road Baton Rouge, LA 70802 Baytown, TX 77520
Hatfield, PA 19440-1770 USA USA
(P) +1.225.383.3813 (P) +1.281.422.6073
(P) +1.215.721.1100 (F) +1.225.388.9689 (F) +1.281.422.6153
+1.800.355.7044 email@example.com firstname.lastname@example.org
(F) +1.215.721.1101 http://estgroup.cwfc.com http://estgroup.cwfc.com
Europe / Middle-East / Africa (EMEA)
EST Group B.V.
2404 HL Alphen aan den Rijn
EST Group Asia
35 Tannery Road
#11-10 Tannery Block
Ruby Industrial Complex
Product animations, instructions, and detailed technical information
are available on our website: http://estgroup.cwfc.com