Tubesheet and tube protector device and a method for making such a device

A tubesheet protector device for use with a boiler having an inlet and an outlet and at least two tubes extending from a tubesheet covering said inlet, comprising:

• at least two elongated shanks adapted to be received in said tubes;
• at least two collars extending radially outwardly from each of said shanks adjacent on end thereof to present an edge spaced radially from said shank, said edge including a sealing surface, wherein said tubes are positioned so that the sealing surfaces of said collars are disposed in a closely mated sealing relationship relative to one another;
• and
• insulating board mounted on said tubesheet wherein said insulating board has at least two holes therein for receiving said shanks, and wherein said insulating board is comprised of silicone oxide (silica) and at least about 66% aluminum oxide (alumina) and has a thermal conductivity no greater than 2.1 BTU-in/hr ft2 ° F. measured at 2500° F.

A device for receiving a fluid, said device comprising:

• a vessel having an inlet and an outlet;
• at least one tube extending through said vessel from said inlet to said outlet;
• a tubesheet closing said inlet and having a hole therein for connecting said tube to said tubesheet at said inlet;
• an insulating board mounted on said tubesheet;
• a polygon-headed ferrule comprised of a shank and adapted to be received in said tube at said inlet, said ferrule having a collar of larger dimensions than the outside diameter of said shank, whereby said insulating board is sandwiched between said collar and said tubesheet, wherein said shank and said collar of said ferrule have a common through bore for transporting fluid from outside said vessel to the interior of said tube, and wherein said insulating board is comprised of silicone oxide (silica) and at least about 66% aluminum oxide (alumina) and has a thermal conductivity no greater than 2.1 BTU-in/hr ft2 ° F. measured at 2500° F.

A method for insulating a tubesheet covering an inlet of a boiler, wherein a tube extends from said tubesheet into said boiler, comprising:

• cutting at least one hole in insulating board;
• mounting said insulating board on said tubesheet;
• and
• inserting a polygon-headed ferrule, comprised of a shank that is integral with a polygon shaped collar, through said hole in said insulating board and into said tube, and wherein said insulating board is comprised of silicone oxide (silica) and at least about 66% aluminum oxide (alumina) and has a thermal conductivity no greater than 2.1 BTU-in/hr ft2 ° F. measured at 2500° F.