System and method for connecting duct components in a boiler

1. A system for interconnecting duct sections of a solids return system of a boiler, comprising:

a first conduit defining a female joint portion;

a second conduit defining a male joint portion that is received by the female joint portion;

a lateral breach formed between an outer peripheral surface of the male joint portion and an inner peripheral surface of the female joint portion; and

a rope seal positioned within the lateral breach and being configured to inhibit the incursion of solids into the lateral breach;

wherein the rope seal is positioned radially outward of the outer peripheral surface of the male joint portion and radially inward of the inner peripheral surface of the female joint portion;

wherein the rope seal is a double rope seal having a first fiber rope and a second fiber rope axially adjacent to one another within the lateral breach;

a steel wire anchoring the first fiber rope and the second fiber rope to the second conduit;

a second refractory material lining an inner periphery of the second conduit; and

a hex mesh securing the second refractory material to the second conduit.

2. The system of claim 1 , wherein:

the first fiber rope and the second fiber rope are ceramic fiber ropes.

3. The system of claim 1 , wherein:

the hex mesh is about 25 millimeter to about 50 millimeter stainless steel hex mesh with internal lances.

4. The system of claim 1 , further comprising:

an insulating pillow received about the male joint portion and abutting a distal end surface of the female joint portion.

5. The system of claim 4 , further comprising:

a second wire securing the insulating pillow to the female joint portion.

6. The system of claim 5 , wherein:

the first conduit forms a portion of a solids return duct configured to return separated solids to a furnace; and

the second conduit forms a portion of a seal pot outlet.

7. The system of claim 5 , wherein:

the first conduit forms a portion of a seal pot inlet; and

the second conduit forms a portion of a dipleg configured to receive solids from a separator.

8. An expansion joint for a solids return system, comprising:

a female joint portion;

a male joint portion received by the female joint portion, the male joint portion and the female joint portion forming a lateral breach therebetween;

a double rope seal positioned within the lateral breach, the double rope seal being configured to accommodate relative lateral movement between the female joint portion and the male joint portion;

wherein the double rope seal includes a first fiber rope and a second fiber rope axially adjacent to one another within the lateral breach;

a steel wire anchoring the first fiber rope and the second fiber rope to the male joint portion; and

an insulating pillow received about the male joint portion and abutting a distal end surface of the female joint portion, the insulating pillow being configured to accommodate relative axial movement between the female joint portion and the male joint portion.

9. The expansion joint of claim 8 , wherein:

the first fiber rope and the second fiber rope are ceramic fiber ropes.

10. The expansion joint of claim 8 , wherein:

the insulating pillow is secured to the female joint portion.

11. The expansion joint of claim 10 , further comprising:

a refractory material lining an inner periphery of the male joint portion; and

a hex mesh securing the second refractory material to the male joint portion.

12. The expansion joint of claim 8 , wherein:

the female joint portion forms a part of a solids return duct configured to return separated solids to a furnace; and

the male joint portion forms a part of a seal pot outlet.

13. A method for interconnecting duct sections of a solids return system, comprising the steps of:

securing a sealing element to a male joint portion of a second conduit;

securing an insulating pillow to a female joint portion of a first conduit;

aligning axially the male joint portion of the second conduit with a female joint portion of a first conduit to form a lateral breach between an outer peripheral surface of the male joint portion and an inner peripheral surface of the female joint portion; and

positioning the sealing element within the lateral breach;

wherein the insulating pillow is configured to be received about the male joint portion and abut a distal end surface of the female joint portion when the second conduit is aligned with the first conduit;

wherein the sealing element is configured to accommodate lateral movement between the first conduit and the second conduit;

wherein the sealing element is a double rope seal having a first ceramic fiber rope and a second ceramic fiber rope axially adjacent to one another within the lateral breach, with a steel wire anchoring the first fiber rope and the second fiber rope to the second conduit; and

wherein the insulating pillow is configured to accommodate axial movement between the first conduit and the second conduit.

14. The method according to claim 13 , further comprising the step of:

securing a refractory material to the male joint portion with a hex mesh.

15. A system for interconnecting duct sections of a solids return system of a boiler, comprising:

a first conduit defining a female joint portion;

a second conduit defining a male joint portion that is received by the female joint portion;

a lateral breach formed between an outer peripheral surface of the male joint portion and an inner peripheral surface of the female joint portion;

a rope seal positioned within the lateral breach and being configured to inhibit the incursion of solids into the lateral breach;

wherein the rope seal is positioned radially outward of the outer peripheral surface of the male joint portion and radially inward of the inner peripheral surface of the female joint portion;

wherein the rope seal is a double rope seal having a first fiber rope and a second fiber rope axially adjacent to one another within the lateral breach, and a steel wire anchoring the first fiber rope and the second fiber rope to the second conduit;

an insulating pillow received about the male joint portion and abutting a distal end surface of the female joint portion.