Premium Heat Exchanger Header Plugs, Air Cooler Header Plugs, and Shoulder Plugs in all alloys and pressure classes. ASME B16.11 certified. Ready stock. Worldwide export.
Header Plug Supplier, Manufacturer & Exporter in India
Jade Alloys is a leading Header Plug Manufacturer and Supplier in India, serving industries worldwide with precision-engineered, high-integrity sealing solutions. Our Header Plugs also known as Shoulder Plugs or Hex Plugs are used extensively in heat exchangers, air coolers, boilers, manifolds, and pressure vessel headers to create a reliable, leak-proof seal.
Every plug is manufactured from certified mill material, precision-machined to tight tolerances, and tested to relevant ASME, ASTM, MSS, and BS standards. We maintain a large ready stock across all materials, sizes, and pressure classes for immediate dispatch to clients across the globe.
What is a Header Plug?
A Header Plug (also called a Shoulder Plug) is a forged or machined threaded component designed to seal the tube-sheet holes or header bores of heat exchangers and air-cooled heat exchangers (ACHEs). When a tube bundle fails or requires bypassing, the corresponding header hole is sealed using a header plug to maintain system pressure without shutting down the entire unit.
Unlike tube plugs that are driven inside a tube, Air Cooler Header Plugs are screwed into a tapped bore in the header box making material grade, thread form, and pressure rating the critical selection criteria.
Types of Header Plugs
Header Plugs are available in several configurations to match your header geometry, thread standard, and installation method.
Hex Head (Shoulder) Plug
The most common type. Features a hexagonal shoulder/head for wrench engagement and a tapered or straight thread shank. Ideal for high-pressure headers.
Threaded / Screwed Plug
Externally threaded plug that screws directly into a tapped header bore. Available in NPT, BSP, BSPT, and UNF thread forms.
Blind Header Plug
Used to completely seal an open tube-sheet port. Provides a flat flush face once installed, suitable for high-pressure and temperature applications.
Socket Weld Header Plug
Designed for socket weld connections. Once welded, it provides a permanent, leak-proof seal that is preferred in critical service environments.
Forged Hex Plug
Manufactured by open or close die forging for maximum grain structure integrity. Preferred for pressure classes 3000 LBS, 6000 LBS, and 9000 LBS.
Air Cooler Header Plug
Specifically designed for air-cooled heat exchanger (ACHE) header boxes. Features precise thread engagement to withstand vibration and thermal cycling.
Header Plug Materials
We supply Header Plugs in a comprehensive range of alloys to meet the specific corrosion, temperature, and pressure requirements of your application.
Duplex Steel Header Plugs
UNS S31803 / S32205
Super Duplex Steel Header Plugs
UNS S32750 / S32760
Inconel / Incoloy Header Plugs
625, 825, 600, 718
Monel Header Plugs
Monel 400, K500
Hastelloy Header Plugs
C276, C22
Carbon Steel Header Plugs
SA105 , ASTM A105
Titanium Header Plugs
Grade 2, Grade 5
Nickel Alloys Header Plugs
Nickel 200 / 201
Copper Nickel Header Plugs
70/30, 90/10
Header Plug Specifications
The table below covers the key dimensional, thread, and pressure parameters applicable across all material grades of Header Plugs supplied by Jade Alloys.
| Parameter | Detail |
|---|---|
| Dimensions Standard | ASME B16.11, MSS SP-79, MSS SP-83, MSS SP-95, MSS SP-97, BS 3799 |
| Material Standards | ASTM A182 / ASME SA182, ASTM A105, ASTM A276, and alloy-specific equivalents |
| Plug Type | Forged / Threaded / Screwed / Hex Shoulder Plug / Blind Plug / Socket Weld |
| Pressure Class | 2000 LBS, 3000 LBS, 6000 LBS, 9000 LBS |
| Sizes (NPS) | 1/8″ to 4″ (and larger on request) |
| Surface Finish | Plain, Electro-polished, Passivated, Pickled & Passivated |
| Max Service Temp. | Material dependent – up to 870°C (SS grades); higher for nickel alloys |
| Testing | Hardness, Hydrostatic, Dye Penetrant (DP), Magnetic Particle (MP), Chemical Analysis |
| Certifications | EN 10204 3.1 / 3.2, NABL-approved lab, PED compliant, Third-party inspection |
Thread Types
Header Plugs are available in all standard thread forms. Selecting the correct thread is essential for pressure-tight sealing and our technical team is available to guide your selection.
- NPT – National Pipe Taper (ANSI B1.20.1)
- BSP – British Standard Pipe Parallel
- BSPT – British Standard Pipe Taper
- UNF – Unified National Fine
- Metric Thread (ISO 965)
- NPSM – Straight Pipe
Header Plug Sizes
| NPS (Nominal Pipe Size) | Pressure Class 2000 LBS | Pressure Class 3000 LBS | Pressure Class 6000 LBS | Pressure Class 9000 LBS |
|---|---|---|---|---|
| 1/8″ | ✓ | ✓ | ✓ | ✓ |
| 1/4″ | ✓ | ✓ | ✓ | ✓ |
| 3/8″ | ✓ | ✓ | ✓ | ✓ |
| 1/2″ | ✓ | ✓ | ✓ | ✓ |
| 3/4″ | ✓ | ✓ | ✓ | ✓ |
| 1″ | ✓ | ✓ | ✓ | ✓ |
| 1¼” | ✓ | ✓ | ✓ | – |
| 1½” | ✓ | ✓ | ✓ | – |
| 2″ | ✓ | ✓ | ✓ | – |
| 2½” – 4″ | On Request | On Request | On Request | – |
Applications of Header Plugs
- Header Plugs serve a critical sealing role across a wide range of industrial systems wherever pressure-tight closure of tube-sheet or manifold ports is required.
- Heat Exchanger Tube Sheet Sealing
- Air Cooled Heat Exchangers (ACHE)
- Boiler & Pressure Vessel Headers
- Manifold & Piping Systems
- Refineries & Process Plants
- LNG & Gas Processing Units
- Power Generation Boilers
- Offshore & Subsea Equipment
- Chemical & Petrochemical Plants
- Desalination Plants
- Fertiliser & Urea Plants
- Pharmaceuticals & Food Processing
Industries Served
Oil & Gas | Petrochemical | Power Generation | Chemical Processing | Refinery | Marine & Offshore | LNG / Gas | Desalination | Fertiliser | Pharmaceutical | Food & Beverage | Aerospace | Nuclear | Pulp & Paper
Related Header Plug Grades
Explore our complete range of Header Plugs by material. Each grade page includes full specifications, chemical composition, mechanical properties, and ready-stock inventory.
Frequently Asked Questions
What is a Header Plug used for?
A Header Plug is used to seal the tapped bores in the header box or tube sheet of heat exchangers and air coolers. When a tube fails, the corresponding header bore is plugged to isolate that tube and allow the unit to continue operating. They are also used to seal unused ports in manifolds and piping headers.
What materials are Header Plugs available in?
We supply Header Plugs in Stainless Steel (304, 316, 321, 347), Duplex and Super Duplex Steel, Carbon Steel (SA105), Inconel, Monel, Hastelloy, Titanium, and Copper Nickel alloys.
What pressure classes are available?
We manufacture Header Plugs in 2000 LBS, 3000 LBS, 6000 LBS, and 9000 LBS pressure classes.
What thread types are available?
Available thread forms include NPT, BSP, BSPT, UNF, Metric (ISO 965), and NPSM. Our technical team can help select the correct thread for your application.
