Sealing assembly for use with a pressurized vessel and methods of assembling the same

1. A method for assembling a seal assembly, said method comprising:

coupling a first ring within a vessel;

coupling a second ring within the vessel;

coupling a first seal layer between the first ring and the second ring such that the first seal layer contacts at least the first ring;

forming a plurality of leaves within the first seal layer;

coupling a second seal layer to the first seal layer such that the second seal layer contacts the second ring, the second seal layer including a plurality of leaves defined therein;

coupling a baffle to the first ring, such that a spacer extends radially outward from the baffle; and

coupling a protector to the first seal layer.

2. A method in accordance with claim 1 further comprising:

aligning the plurality of leaves such that a first leaf of the first seal layer partially overlaps at least two leaves of the second seal layer.

3. A method in accordance with claim 1 further comprising coupling the second ring to a wall of a syngas cooler.

4. A method in accordance with claim 3 further comprising coupling at least one support between the second ring and the wall.

5. A method in accordance with claim 1 further comprising coupling the first ring to an internal structure within a syngas cooler.

6. A method in accordance with claim 5 further comprising coupling at least one of a connector and a shim between the first ring and the internal structure.

7. A method in accordance with claim 1 further comprising positioning the inner ring using a cord and a plurality of hooks defined on the first ring and the second ring such that the first seal layer engages the second ring.

8. A seal assembly for use within a pressurized vessel, said seal assembly comprising:

a first ring;

a second ring spaced radially outwardly from said first ring;

a first seal layer coupled to said first ring, wherein said first seal layer contacts at least said first ring and comprises a plurality of generally axially-extending leaves, said plurality of leaves spaced apart such that a gap is defined between adjacent leaves, said gap includes slotted portion and a relief aperture extending through said seal layer;

a second seal layer coupled to said first seal layer, said second seal layer contacts said second ring;

a baffle coupled to said first ring;

a spacer extending radially outward from said baffle; and

a protector coupled to said first seal layer.

9. A seal assembly in accordance with claim 8 wherein each of said first seal layer and said second seal layer comprises a plurality of generally axially-extending leaves oriented such that a gap is defined between adjacent said leaves, wherein each leaf of said plurality of leaves has a substantially non-planar cross-sectional shape said gap includes a slotted portion and a relief aperture extending through each seal layer.

10. A seal assembly in accordance with claim 8 wherein said first seal layer is substantially concentrically aligned with said second seal layer.

11. A seal assembly in accordance with claim 8 further comprising at least one stiffener coupled to said first ring.

12. A syngas cooler comprising:

a shell wall;

a component coupled radially inward from said shell wall such that a gap is defined between said shell wall and said component; and

a seal assembly coupled within said gap, said seal assembly comprising:

a first ring coupled to said component;

a second ring coupled to said shell wall;

a first seal layer coupled to said first ring, wherein said first seal layer contacts at least said first ring and comprises a plurality of generally axially-extending leaves, said plurality of leaves spaced apart such that a gap is defined between adjacent leaves, said gap includes slotted portion and a relief aperture extending through said seal layer;

a second seal layer coupled to said first seal layer, said second seal layer contacts said second ring;

a baffle coupled to said first ring;

a spacer extending radially outward from said baffle; and

a protector coupled to said first seal layer.

13. A syngas cooler in accordance with claim 12 wherein each of the first seal layer and the second seal layer comprising a plurality of generally axially-extending leaves oriented such that a gap is defined between adjacent said leaves, said gap includes a slotted portion and a relief aperture extending through each seal layer.

14. A syngas cooler in accordance with claim 12 wherein said seal assembly further comprises at least one support coupled between said second ring and said shell wall.

15. A syngas cooler in accordance with claim 12 wherein said seal assembly further comprises at least one of a connector and a shim coupled between said first ring and said component.