RECOMMENDED TUBESHEET PLUG SIZES

I. PLUGS FOR TUBESHEET HOLES AFTER TUBE REMOVAL

TUBESHEET
ALPHA

DS DL
DH

L
TABLE I. PLUGS FOR TUBESHEET HOLES AFTER TUBE REMOVAL
TUBE HOLE PLUG - PLUG - PLUG ALPHA EXTENSION
DIA. LARGE END OD SMALL END OD LENGTH OUTSIDE
(DH) (DL) (DS) (L) TUBESHEET (E)
1/4” 0.328” 0.171” 1.968” o
0.984”
6.35 mm 8.35 mm 4.35 mm 50 mm 2.29 25 mm
3/8” 0.453” 0.296” 1.968” o
0.984”
9.53 mm 11.53 mm 7.53 mm 50 mm 2.29 25 mm
1/2” 0.578” 0.421” 1.968” o
0.984”
12.7 mm 14.7 mm 10.7 mm 50 mm 2.29 25 mm
5/8” 0.703” 0.546” 1.968” o
0.984”
15.87 mm 17.87 mm 13.87 mm 50 mm 2.29 25 mm
3/4” 0.828” 0.671” 1.968” o
0.984”
19.05 mm 21.05 mm 17.05 mm 50 mm 2.29 25 mm
1” 1.078” 0.921” 2.007” o
1.00”
25.4 mm 27.4 mm 23.4 mm 51 mm 2.245 25.4 mm
1 1/4” 1.328” 1.171” 2.007” o
1.003”
31.75 mm 33.75 mm 29.75 mm 51 mm 2.245 25.5 mm
1 1/2” 1.578” 1.421” 2.007” o
1.003”
38.1 mm 40.1 mm 36.1 mm 51 mm 2.245 25.5 mm
2” 2.078” 1.921” 2.007” o
1.003”
50.8 mm 52.8 mm 48.8 mm 51 mm 2.245 25.5 mm

II. PLUGS FOR TUBESHEET HOLES WITH TUBES IN PLACE

 TABLE II - PLUGS FOR TUBESHEET HOLES WITH TUBES IN PLACE

Tube Size B.W.G Tube Hole Plug- Large Plug- Small Plug  Extension
DIA. End OD End OD Length outside
( DH ) ( DL ) ( DS ) (L) Tubesheet
(E)
1/4 in. 22 0.194 in. 0.273 in. 0.115 in. 1.968 in. 2.29  0.984 in.
( 6.35mm) 4.93 mm 6.93 mm 2.93 mm 50 mm 25.0 mm
1/4 in. 24 0.206 in. 0.285 in. 0.127 in. 1.968 in. 2.29  0.984 in.
( 6.35mm) 5.23 mm 7.23 mm 3.23 mm 50 mm 25.0 mm
1/4 in. 26 0.214 in. 0.293 in. 0.135 in. 1.968 in. 2.29  0.984 in.
( 6.35mm) 5.43 mm 7.43 mm 3.43 mm 50 mm 25.0 mm
1/4 in. 27 0.218 in. 0.297 in. 0.139 in. 1.968 in. 2.29  0.984 in.
( 6.35mm) 5.54 mm 7.54 mm 3.54 mm 50 mm 25.0 mm
3/8 in. 18 0.277 in. 0.356 in. 0.198 in. 1.968 in. 2.29  0.984 in.
(9.53mm) 7.035 mm 9.035 mm 5.035 mm 50 mm 25.0 mm
3/8 in. 20 0.305 in. 0.384 in. 0.226 in. 1.968 in. 2.29  0.984 in.
(9.53mm) 7.747 mm 9.747 mm 5.747 mm 50 mm 25.0 mm
3/8 in. 22 0.319 in. 0.398 in. 0.240 in. 1.968 2.29  0.984 in.
(9.53mm) 8.103 mm 10.103 mm 6.103 mm 50 mm 25.0 mm
3/8 in. 24 0.331 in. 0.409 in. 0.253 in. 1.968 in. 2.29  0.984 in.
(9.53mm) 8.41 mm 10.407 mm 6.407 mm 50 mm 25.0 mm
1/2 in. 16 0.370 in. 0.449 in. 0.291 in. 2.0 in. 2.25  1.004 in.
(12.7mm) 9.398 mm 11.398 mm 7.398 mm 51 mm 25.5 mm
1/2 in. 18 0.402 in. 0.480 in. 0.323 in. 2.0 in. 2.25  1.004 in.
(12.7mm) 10.21 mm 12.21 mm 8.21 mm 51 mm 25.5 mm
1/2 in. 20 0.430 in. 0.509 in. 0.351 in. 2.0 in. 2.25  1.004 in.
( 12.7 ) 10.92 mm 12.922 mm 8.922 mm 51 mm 25.5 mm
1/2 in. 22 0.444 in. 0.523 in. 0.365 in. 2.0 in. 2.25  1.004 in.
(12.7mm) 11.28 mm 13.277 mm 9.277 mm 51 mm 25.5 mm
5/8 in. 12 0.407 in. 0.486 in. 0.328 in. 2.0 in. 2.25  1.004 in.
(15.87mm) 10.34 mm 12.337 mm 8.337 mm 51 mm 25.5 mm
5/8 in. 13 0.435 in. 0.514 in. 0.356 in. 2.0 in. 2.25  1.004 in.
(15.87mm) 11.05 mm 13.049 mm 9.049 mm 51 mm 25.5 mm
5/8 in. 14 0.459 in. 0.538 in. 0.380 in. 2.0 in. 2.25  1.004 in.
(15.87mm) 11.66 mm 13.658 mm 9.658 mm 51 mm 25.5 mm
5/8 in. 15 0.481 in. 0.559 in. 0.402 in. 2.0 in. 2.25  1.004 in.
(15.87mm) 12.217 mm 14.217 mm 10.217 mm 51 mm 25.5 mm
5/8 in. 16 0.495 in. 0.574 in. 0.416 in. 2.0 in. 2.25  1.004 in.
(15.87mm) 12.57 mm 14.573 mm 10.573 mm 51 mm 25.5 mm
 TABLE 11 - PLUGS FOR TUBESHEET HOLES WITH TUBES IN PLACE,
CON’D.

B.W.G Tube Hole Plug- Large Plug- Small Plug  Extension

Tube Size DIA. End OD End OD Length outside
( DH ) ( DL ) ( DS ) (L) Tubesheet
(E)
5/8 in. 18 0.527 in. 0.606 in. 0.448 in. 2.0 in. 2.25  1.004 in.
(15.87mm) 13.385 mm 15.385 mm 11.385 mm 51 mm 25.5 mm
5/8 in. 19 0.541 in. 0.619 in. 0.462 in. 2.0 in. 2.25  1.004 in.
(15.87mm) 13.74 mm 15.741 mm 11.741 mm 51 mm 25.5 mm
5/8 in. 20 0.555 in. 0.634 in. 0.476 in. 2.0 in. 2.25  1.004 in.
(15.87mm) 14.097 mm 16.097 mm 12.097 mm 51 mm 25.5 mm
3/4 in. 10 0.482 in. 0.561 in. 0.403 in. 2.0 in. 2.25  1.004 in.
(19.05mm) 12.24 mm 14.24 mm 10.24 mm 51 mm 25.5 mm
3/4 in. 11 0.510 in. 0.589 in. 0.431 in. 2.0 in. 2.25  1.004 in.
(19.05mm) 12.954 mm 14.954 mm 10.954 mm 51 mm 25.5 mm
3/4 in. 12 0.532 in. 0.611 in. 0.453 in. 2.0 in. 2.25  1.004 in.
(19.05mm) 13.51 mm 15.51 mm 11.51 mm 51 mm 25.5 mm
3/4 in. 13 0.560 in. 0.639 in. 0.481 in. 2.0 in. 2.25  1.004 in.
(19.05mm) 14.22 mm 16.22 mm 12.22 mm 51 mm 25.5 mm
3/4 in. 14 0.584 in. 0.663 in. 0.505 in. 2.0 in. 2.25  1.004 in.
(19.05mm) 14.833 mm 16.833 mm 12.833 mm 51 mm 25.5 mm
3/4 in. 15 0.606 in. 0.685 in. 0.527 in. 2.0 in. 2.25  1.004 in.
(19.05mm) 15.39 mm 17.39 mm 13.39 mm 51 mm 25.5 mm
3/4 in. 16 0.620 in. 0.698 in. 0.541 in. 2.0 in. 2.25  1.004 in.
(19.05mm) 15.74 mm 17.74 mm 13.74 mm 51 mm 25.5 mm
3/4 in. 17 0.634 in. 0.713 in. 0.555 in. 2.0 in. 2.25  1.004 in.
(19.05mm) 16.10 mm 18.10 mm 14.10 mm 51 mm 25.5 mm
3/4 in. 18 0.652 in. 0.737 in. 0.573 in. 2.0 in. 2.25  1.004 in.
(19.05mm) 16.56 mm 18.56 mm 14.56mm 51 mm 25.5 mm
3/4 in. 20 0.680 in. 0.759 in. 0.601 in. 2. 0 in. 2.25  1.004 in.
(19.05mm) 17.27 mm 19.27 mm 15.27 mm 51 mm 25.5 mm
1 in. 8 0.670 in. 0.749 in. 0.591 in. 2.0 in. 2.25  1.004 in.
(25.4mm) 17.02 mm 19.02 mm 15.02 mm 51 mm 25.5 mm
1 in. 10 0.732 in. 0.811 in. 0.653 in. 2.0 in. 2.25  1.004 in.
(25.4mm) 18.59 mm 20.5 9mm 16.59 mm 51 mm 25.5 mm
1 in. 11 0.760 in. 0.839 in. 0.681 in. 2.0 in. 2.25  1.004 in.
(25.4mm) 19.30 mm 21.30 mm 17.30 mm 51 mm 25.5 mm
1 in. 12 0.782 in. 0.861 in. 0.703 in. 2.0 in. 2.25  1.004 in.
(25.4mm) 19.86 mm 21.86 mm 17.86 mm 51 mm 25.5 mm
1 in. 13 0.810 in. 0.889 in. 0.731 in. 2.0 in. 2.25  1.004 in.
(25.4mm) 20.57 mm 22.57 mm 18.57 mm 51 mm 25.5 mm
 TABLE 11 - PLUGS FOR TUBESHEET HOLES WITH TUBES IN PLACE,
CON’D.

Tube Size B.W.G Tube Hole Plug- Large Plug- Small Plug  Extension
DIA. End OD End OD Length outside
( DH) ( DL) ( DS ) (L) Tubesheet
( E)
1 in. 14 0.834 in. 0.913 in. 0.755 in. 2.0 in. 2.25  1.004 in.
(25.4mm) 21.183 mm 23.183 mm 19.183 mm 51 mm 25.5 mm
1 in. 15 0.856 in. 0.935 in. 0.777 in. 2.0 in. 2.25  1.004 in.
(25.4mm) 21.74 mm 23.74 mm 19.74 mm 51 mm 25.5 mm
1 in. 16 0.870 in. 0.949 in. 0.791 in. 2.0 in. 2.25  1.004 in.
(25.4mm) 22.098 mm 24.098 mm 20.098 mm 51 mm 25.5 mm
1 in. 18 0.902 in. 0.981 in. 0.823 in. 2.0 in. 2.25  1.004 in.
(25.4mm) 22.91 mm 24.91 mm 20.91 mm 51 mm 25.5 mm
1 in. 20 0.930 in. 1.01 in. 0.852 in. 2.0 in. 2.25  1.004 in.
(25.4mm) 23.62 mm 25.62 mm 21.62 mm 51 mm 25.5 mm
1.25 in. 7 0.890 in. 0.969 in. 0.811 in. 2.0 in. 2.25  1.004 in.
(31.75mm) 22.606 mm 24.606 mm 20.606 mm 51 mm 25.5mm
1.25 in. 8 0.920 in. 0.999 in. 0.841 in. 2.0 in. 2.25  1.00 4 in.
(31.75mm) 23.37 mm 25.37 mm 21.37 mm 51 mm 25.5 mm
1.25 in. 10 0.982 in. 1.061 in. 0.903 in. 2. 0 in. 2.25  1.004 in.
(31.75mm) 24.94 mm 26.94 mm 22.94 mm 51 mm 25.5 mm
1.25 in. 11 1.01 in. 1.089 in. 0.931 in. 2.0 in. 2.25  1.004 in.
(31.75mm) 25.65 mm 27.65 mm 23.65 mm 51 mm 25.5 mm
1.25 in. 12 1.032 in. 1.111 in. 0.953 in. 2.0 in. 2.25  1.004 in.
(31.75mm) 26.21 mm 28.21 mm 24.21 mm 51 mm 25.5 mm
1.25 in. 13 1.060 in. 1.139 in. 0.981 in. 2.0 in. 2.25  1.004 in.
(31.75mm) 26.92 mm 28.92 mm 24.92 mm 51 mm 25.5 mm
1.25 in. 14 1.084 in. 1.163 in. 1.005 in. 2.0 in. 2.25  1.004 in.
(31.75mm) 27.53 mm 29.53 mm 25.53 mm 51 mm 25.5 mm
1.25 in. 16 1.120 in. 1.198 in. 1.041 in. 2.0 in. 2.25  1.004 in.
(31.75 mm) 28.45 mm 30.45 mm 26.45 mm 51 mm 25.5 mm
1.25 in. 18 1.152 in. 1.231 in. 1.073 in. 2.0 in. 2.25  1.004 in.
(31.75mm) 29.26 mm 31.26 mm 27.26 m m 51 mm 25.5 mm
1.25 in. 20 1.180 in. 1.259 in. 1.101 in. 2.0 in. 2.25  1.004 in.
(31.75mm) 29.97 mm 31.97 mm 27.97 mm 51 mm 25.5 mm
1.5 in. 10 1.232 in. 1.311 in. 1.153 in. 2.0 in. 2.25  1.004 in.
(38.1mm) 31.29 mm 33.29 mm 29.29 mm 51 mm 25.5 mm
1.5 in. 12 1.282 in. 1.361 in. 1.203 in. 2.0 in. 2.25  1.004 in.
(38.1mm) 32.56 mm 34.56 mm 30.56 mm 51 mm 25.5 mm
1.5 in. 14 1.334 in. 1.413 in. 1.255 in. 2.0 in. 2.25  1.004 in.
(38.1mm) 33.88 mm 35.88 mm 31.88 mm 51 mm 25.5 mm
 TABLE 11 - PLUGS FOR TUBESHEET HOLES WITH TUBES IN PLACE, CON’D.

Tube Size B.W.G Tube Hole Plug- Large Plug- Small Plug  Extension
DIA. End OD End OD Length outside
( DH ) ( DL ) ( DS ) (L) Tubesheet
(E)
1.5 in. 16 1.370 in. 1.448 in. 1.291 in. 2.0 in. 2.25  1.004 in.
(38.1mm) 34.79 mm 36.79 mm 32.79 mm 51 mm 25.5 mm
2 in. 11 1.760 in. 1.839 in. 1.681 in. 2.0 in. 2.25  1.004 in.
(50.8mm) 44.704 mm 46.704 mm 42.704 mm 51 mm 25.5 mm
2 in. 12 1.782 in. 1.861 in. 1.703 in. 2.0 in. 2.25  1.004 in.
(50.8mm) 45.26 mm 47.26 mm 43.26 mm 51 mm 25.5 mm
2 in. 13 1.810 in. 1.889 in. 1.73 in. 2.0 in. 2.25  1.004 in.
(50.8mm) 45.97 mm 47.97 mm 43. 97 mm 51 mm 25.5 mm
2 in. 14 1.834 in. 1.913 in. 1.755 in. 2.0 in. 2.25  1.004 in.
(50.8mm) 46.58 mm 48.58 mm 44.58 mm 51 mm 25.5 mm