EST

Group

G-Series Tube Testing Guns

Asia Pacific Sales Meeting 2015

1 | December 8, 2023 | Proprietary © 2014 Curtiss-Wright

 G-Series Heat Exchanger Tube Testing Guns

• What are G-Series Test Guns?

• G-Series Test Guns are a quick and effective means to test
either tube or tube to sheet integrity in tubular heat exchangers

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 G-Series Tube Testing Systems

Typical Product
Applications

Condensers Shell and Tube Heat Boilers Air Cooled Heat Shipping/
Exchangers Exchangers Shipbuilding

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 G-Series Tube Testing Systems

Major Markets Served

Worldwide

Chemical
Oil Refining Nuclear Power Processing Fertilizer Plants Fossil Power

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 G-Series Tube Testing Systems

Why are Test Guns Needed?

• All tubular heat exchangers
eventually have tube or tube joint
failures
• Failed tubes need to be identified in
order to plugged

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 G-Series Tube Testing Systems

What Testing Methods are Currently in Use?

Eddy Current Testing (ECT)
 Uses Electromagnetic induction to
find defects
 Requires Highly Trained Contractors
 Highly dependent on technician
 Only used in conductive tubes
Shell Side Pressurization
 Fill Shell with water, and pressurize
 Time consuming
 Safety concerns

Acoustics Other
 Acoustic Eye:  Tracer Gas
 Listen for tube leaks  Helium or Sulfur-Hexafloride
 Requires trained subcontractor  Shaving cream
 Ultraprobe:  Plastic wrap
 Difficult in noisy locations  Dimple plugs

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 G-Series Tube Testing Systems

How does the G-150 work?

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 G-Series Tube Testing Systems

How does it work?

 Use sizing chart to determine correct Seal and
Washer set, see DC2050
 Make sure correct seal size and support tubes are
installed
 Make sure tubes are free of debris and loose
scale
 Attach air supply to plugging gun
 Insert guns into tube
 Activate injection gun by pressing control valve
 Hold pressure for 15 seconds and observe gauge.
Loss of pressure indicates a tube leak.
 If there’s no pressure loss, press dump valve to
release pressure and relax seals
 Move to next tube
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 G-Series Tube Testing Systems

G-150 Key Features

 Standard Plant Air: 40 to 125 PsiG (2.7 to 8.5 BarG)
 Standard Seals: Neoprene, Optional: Fluro-
Elastomers
 Ability to tests from 3 to 10 tubes per minute
 Tube Sizes
 G-150 Model - 0.28” to 1.23 (7.1 to 31.2mm)
 G-150A Model – 1.24” to 2.53” (31.5 to 64.3mm)
 Optional digital gauge increases sensitivity – find
smaller leaks faster
 Quality Assurance System: Certified to ISO 9000

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 G-Series Tube Testing Systems

G-150A Key Features

 G-150A Testing Guns Operate in Tube Sizes from
1.24” to 2.53” ID – (31.5 mm to 64.3 mm) (Larger
applications are possible)
 Weights less than 2.4.lb (1.1 kg ) each
 G-Series Guns come complete with a durable tool box
with internal compartments for storage of Seal and
Washer Sets, Support Tube Assemblies & extensions
 Optional digital gauge increases sensitivity – find
smaller leaks faster

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 G-Series Tube Testing Systems

How does it work?

 Use sizing chart to determine correct Seal and Washer,
see DC2080
 Make sure correct Seal size and Support Tubes are
installed
 Make sure tubes are free of debris and loose scale
 Attach air supply to plugging gun
 Insert guns into tube
 Activate injection gun by pressing control valve
 Hold pressure for 15 seconds and observe gauge. Loss of
pressure indicates a tube leak.
 If there’s no pressure loss, press dump valve to release
pressure and relax seals
 Move to next tube
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 G-Series Tube Testing Systems

G-250 Vacuum Test Gun Key Features

 The Tapered Seal design allows testing of a large
range of tube ID’s without changing out the Seals,
washers or support rods
 Only three Conical Seal Sizes (seals are included)
 Small: 0.28” to 0.68” (7.1mm to 17.3mm) ID tubes
 Medium: 0.64” to 1.45” (16.3 mm to 36.8 mm) ID
tubes
 Large: 1.49” to 2.5” (37.8 mm to 63.5 mm) ID tubes
 Operates on Plant Air Supply: 40 – 125 PsiG (2.7 to
8.5 BarG) utilizes integral venturi to evacuate tube
 Standard Seal Materials: Neoprene
 Optional digital gauge increases sensitivity – find
smaller leaks faster

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 G-Series Tube Testing Systems
How does it work?
 Use sizing chart to determine correct Seal and
Washer size, use DC# 2090
 Make sure correct support tube is installed
 Make sure tubes are free of debris
 Attach air supply to test gun
 Insert gun into tube, insert T-handle into opposite
tube end
 Activate vacuum gun by pressure air control valve.
Air flow through the Venturi evacuates the tube
 Release air control valve to isolate tube, hold
vacuum for 15 seconds, a loss of vacuum indicates
a tube leak
 If tube is not leaking, rock test gun to release
vacuum, proceed to next tube

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 G-Series Tube Testing Systems
G-450 Tube Testing Gun Benefits
 Test straight –heat exchanger tubes without removing both heads
 Ideal for hydrogen coolers/turbine oil coolers
 Tube Sizes: 0.50” to 1.23” (12.7 to 31.3mm) ID
 Rod and Extension Tubes assemblies available in 1ft. to 6 ft. (0.3 m to 1.8 m) lengths.
Can be assembled to test tubes up to 24 ft (7.3m) long
 Complete Kit Available: Consists of a G-450 Air Injection Gun, an Extension Tube
Assembly with Washer and Seals Set to the distance between the two tube sheets
 Optional digital gauge increases sensitivity – find smaller leaks faster

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 G-Series Tube Testing Systems
How does it work?
 Use sizing chart to determine correct Seal and Washer
size, see DC2060
 Make sure correct Seal size and Support Tube size and
length are installed
 Make sure tubes are free of debris and loose scale
 Insert Support Rod and Tube assembly into the tube
 Attach gun to assembly
 Activate gun by pressure air control valve
 Allow pressure to build, release air control valve to isolate
tube, hold pressure for 15 seconds
 If there’s no indication of pressure drop, press bleed
valve to depressurize tube
 Remove test gun from rod assembly, remove rod, install
next tube, repeat

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 G-Series Tube Testing Systems
G-650 Vacuum Test Gun – Key features
 Quickly tests tube to tubesheet joints under vacuum
 Interchangeable manifolds allow testing from 3/8” to 1 ¼”
(9.5mm to 31.8mm) OD tubes with standard pitch
 G-650A model can test to 2 ½” (63.5mm) OD Tubes
 Operates on Plant Air Supply: 40 – 125 PsiG (2.7 to 8.5 BarG)
 Standard Seal Materials : Neoprene
 Optional digital gage increases sensitivity – find smaller leaks
faster

Acoustics

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 G-Series Tube Testing Systems
How does it work?
 Use sizing chart to determine correct Seal and Washer
and Manifold size, see DC2070
 Make sure tubes and tubesheet face are free of debris
and loose scale
 Insert test gun into tube
 Activate gun by pressing cylinder control valve, then
press vacuum valve to activate tube
 Hold vacuum for 15 seconds, loss of vacuum indicates a
joint leak
 If no loss of vacuum, press bleed valve, rock gun to
break vacuum

17 | December 8, 2023 | © Curtiss-Wright

 Want More Information?

EST Group
2701 Township Line Road
Hatfield, PA 19440 USA
T: +1.215.721.1100 • F: +1.215-721.1101
E: est-info@curtisswright.com

www.cw-estgroup.com
18 | December 8, 2023 | Proprietary © Curtiss-Wright