IST-WI-109-00

Installing Washers on Flow Screen Plates

Revision No.:00 Rev. Date: 06/08/2022
Print Date August 5, 2022 Page 1 of 7

INSTALLING WASHERS ON FLOW SCREEN PLATES

1 PURPOSE

This Work Instruction (WI) describes the method to tighten down the flow screen washers to ensure the flow screen
plates do not flutter when the boiler is in operation but also not too tight that the flow screen plates cannot expand
thermally.

2 SCOPE

The requirements noted in this document apply to flow screens that utilize either bare studs welded with washer
plates or threaded hold down studs.

3 REFERENCES

3.1 None

4 RESPONSIBILITIES
4.1 Refer to the table below for responsibility requirements:

Installer 1. Compliance with this Work Instruction and other referenced

instructions.
1. Installer has received the necessary training.

Shop Supervisor 2. Compliance to this Work Instruction.

3. Sign-off for any In-process Inspection form is completed.

5 PRELIMINARY CHECKS
5.1 Preliminary Checks – The following checks are to be completed prior to installing liner hardware:

a) Flow screen assembly and stud materials to be checked for conformance to fabrication drawings.

b) Flow screen plates shall be laid over studs as per fabrication drawings. Fabricator shall ensure
spacer plates are correctly placed underneath indicated flow screen plates. Pay careful attention
the screens are lapped in the correct order as indicated on the fabrication drawings.

c) Burrs on studs, washers and flow screen plates are to be ground smooth so components can move
freely over each other without binding.

d) The studs shall be centered on the flow screen plate holes. If studs are not centered, then the holes
in the flow screen plate and stud locations need to be checked against the fabrication drawings for
errors.

This document is the property of PROPAK SYSTEMS LTD. and shall not be disclosed to Others, reproduced in any manner or used for any purpose whatsoever except by
written consent of PROPAK. All printed copies are uncontrolled.
 IST-WI-109-00
Installing Washers on Flow Screen Plates
Revision No.:00 Rev. Date: 06/08/2022
Print Date August 5, 2022 Page 2 of 7

6 SOLID BAR WASHER INSTALLATION PROCEDURE

6.1 After the preliminary checks in Section 5 above have been completed, start the flow screen plate installation
as per the fabrication drawings. Place washers over studs that are protruding through the flow screen in the
center locations while leaving the perimeter edge holes of the flow screen plate for a later step.

6.2 Place modified vice-grip (Figure 1) over smooth stud, with washer, located approximately in the centre of
flow screen plate and tighten. Repeat procedure for all studs along the length of the flow screen plate.

6.3 After the vice grips are installed, starting in the middle of the flow screen plate, hammer the vice grip down
“Hard” (Figure 3) so that the washer is tight against the plate. Repeat the procedure moving out from flow
screen plate centre along the length, alternating from one side of the centre to the other, until all the washers
in the line, on the flow screen plate are tight.

6.4 Check the tightness of the washers by standing on the flow screen plate (Figure 4) immediately adjacent to
two opposing sides of the washer. If a gap opens up (Figure 5) between the washer and the plate, it is not
tight enough and the vice grip at that location needs to be hammered down more, until no gaps open up.

6.5 When no gap appears, weld the stud to the washer in the gap between the vice grip jaws on both sides.
Proceed with all washers in the line along the length of flow screen plate (Figure 2). NOTE: 308L weld wire
is not permitted in welding 316 materials.

6.6 Remove centre vice grip and complete weld around each stud per drawing. Proceed along flow screen plate
length alternating from one side of the centre to the other.

6.7 Using the above procedure, complete all individual washer to stud welds moving from the centre of the flow
screen plate to the long edge.

6.8 After all washers are welded down on a flow screen plate, check that the washers are tight against plate by
standing immediately adjacent to two opposing sides.

6.9 On studs where there is a gap, a piece of 3” schedule 80 (or heavier pipe) will be used to remove the washer
clearance. Centre the pipe over the stud and washer and using a sledge hammer, hit the pipe hard a couple
of times to bend the washer down against the flow screen plate. Re-check for gap and if necessary, repeat
the procedure.

7 THREADED ROD WASHER \ NUT INSTALLATION PROCEDURE

7.1 After the preliminary checks in Section 5 above have been completed, start the flow screen plate installation
as per the fabrication drawings. Place washers over studs that are protruding through the flow screen plate
in the center locations while leaving the perimeter edge holes of the flow screen plate for a later step.

7.2 Starting at the threaded stud located approximately in the centre of the flow screen plate install a nut, of the
material indicated in the drawing. Tighten nut to a torque of approximately 25 foot pounds. Only calibrated
torque wrenches shall be used.

7.3 Repeat the procedure moving out from the centre of the flow screen plate.

7.4 Once the flow screen plate nuts are installed as indicated above, they should be re- torqued to 50 foot
pounds and then backed one quarter turn.
This document is the property of PROPAK SYSTEMS LTD. and shall not be disclosed to Others, reproduced in any manner or used for any purpose whatsoever except by
written consent of PROPAK. All printed copies are uncontrolled.
 IST-WI-109-00
Installing Washers on Flow Screen Plates
Revision No.:00 Rev. Date: 06/08/2022
Print Date August 5, 2022 Page 3 of 7

7.5 Check that nuts are not overtightened by hitting the corner of the washer with a hammer (1 kg steel), the
washer should rotate slightly. If it does not rotate, the nut is installed too tight and should be backed off
another quarter turn (Total half turn after tightening to 50 foot pounds). Check washer tightness again with
a hammer to check for slight rotation.

7.6 Note that if standing immediately adjacent to opposing sides of washer and a gap is apparent between nut
and washer or washer and flow screen plate, the nut is too loose, and the torque will need to be increased
and the tightness re-checked. Washer turns slightly when hit on the corner with a 1 kg steel hammer).

Note: No gap should be visible when standing immediately adjacent to two sides of the washer.

This document is the property of PROPAK SYSTEMS LTD. and shall not be disclosed to Others, reproduced in any manner or used for any purpose whatsoever except by
written consent of PROPAK. All printed copies are uncontrolled.
 IST-WI-109-00
Installing Washers on Flow Screen Plates
Revision No.:00 Rev. Date: 06/08/2022
Print Date August 5, 2022 Page 4 of 7

8 FIGURES

Applies also to
perforated flow
screen plate.
Typical all figures.

Figure 1 – Modified vice-grip

Figure 2 – Multiple vice-grips installed along channel length

This document is the property of PROPAK SYSTEMS LTD. and shall not be disclosed to Others, reproduced in any manner or used for any purpose whatsoever except by
written consent of PROPAK. All printed copies are uncontrolled.
 IST-WI-109-00
Installing Washers on Flow Screen Plates
Revision No.:00 Rev. Date: 06/08/2022
Print Date August 5, 2022 Page 5 of 7

Figure 3 – Vice-grip hammer loading

Acceptable
washer gap
shown

Figure 4 – Washer gap check

This document is the property of PROPAK SYSTEMS LTD. and shall not be disclosed to Others, reproduced in any manner or used for any purpose whatsoever except by
written consent of PROPAK. All printed copies are uncontrolled.
 IST-WI-109-00
Installing Washers on Flow Screen Plates
Revision No.:00 Rev. Date: 06/08/2022
Print Date August 5, 2022 Page 6 of 7

Figure 5 – Improper washer installation

This document is the property of PROPAK SYSTEMS LTD. and shall not be disclosed to Others, reproduced in any manner or used for any purpose whatsoever except by
written consent of PROPAK. All printed copies are uncontrolled.
 IST-WI-109-00
Installing Washers on Flow Screen Plates
Revision No.:00 Rev. Date: 06/08/2022
Print Date August 5, 2022 Page 7 of 7

9 REVISION HISTORY
DETAILED DESCRIPTION OF CHANGES

00 06/08/2022 Issued for Release BB AB

Date Originator Approve
Rev. Reason for Revision
mm/dd/yyyy Initials Initials

This document is the property of PROPAK SYSTEMS LTD. and shall not be disclosed to Others, reproduced in any manner or used for any purpose whatsoever except by
written consent of PROPAK. All printed copies are uncontrolled.