IST-WI-101-02

Installing Washers and Channels on Insulated Duct Walls

Revision No.:02 Rev. Date: 06/08/2022
Print Date June 14, 2022 Page 1 of 9

INSTALLING WASHERS AND CHANNELS ON INSULATED DUCT WALLS

1 PURPOSE

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

2 SCOPE

The requirements noted in this document apply to internally insulated duct systems using a stainless-steel liner
system and a combination of bare and threaded hold down pins.

3 REFERENCES

3.1 Work Instruction WI-064 – Insulating OTSG Walls

3.2 Engineering Specification ES-016 - Structural Fabrication & Internally Lined Ducts

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) Liner, washer and liner channel material to be checked for conformance to fabrication drawings.

b) Insulation density to be checked for conformance to drawings and has been installed per Work
Instruction WI-064 for ducting built at IST\Propak. For ducting manufactured by outside Vendors,
insulation shall be installed per Engineering Specification ES-016.

c) Liner sheets are to be laid over pins and LAPPED IN THE OPPOSITE DIRECTION TO GAS FLOW
as shown below.
Gas Flow Direction Overtop Liners

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-101-02
Installing Washers and Channels on Insulated Duct Walls
Revision No.:02 Rev. Date: 06/08/2022
Print Date June 14, 2022 Page 2 of 9

d) Burrs on liner plates, washers and channel are to be ground smooth so components can move over each
other.

e) The scallop plate pins should be centered on the liner plate holes. If pins are not centered, then the holes in
the liner and pin locations need to be checked against the fabrication drawings. NOTE: It is possible that the
scallop plates may not be welded perpendicular to the casing and if they are rotated perpendicular, the pins
may center themselves in the liner holes.

6 SOLID BAR WASHER INSTALLATION PROCEDURE

6.1 After the preliminary checks in Section 5 above have been completed, start the liner sheet installation
02 adjacent to a duct wall corner. Place washers over pins that are protruding through the sheet in the center
locations while leaving the perimeter edge holes of the sheet for a later step. Refer to pins 1 and 2 in Figure
1.

6.2 Place modified vice-grip (Figure 2) over smooth pin, with washer, located approximately in the centre of
liner sheet and tighten. Repeat procedure for all pins along the length of the sheet.

6.3 After the vice grips are installed, starting in the middle of the sheet, hammer the vice grip down “Hard”
(Figure 4) so that the washer is tight against the sheet. Repeat the procedure moving out from liner plate
centre along the length, alternating from one side of the centre to the other, until all the washers in the line,
on the liner sheet are tight.

6.4 Check the tightness of the washers by standing on the liner sheet (Figure 5) immediately adjacent to two
opposing sides of the washer. If a gap opens up (Figure 6) between the washer and liner 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 pin 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 sheet (Figure 3). NOTE: 308L weld wire is not
permitted in welding 316 materials.

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

6.7 Using the above procedure, complete all individual washer to pin welds moving from the centre of the sheet
to the long edge.

6.8 Once all individual washer to pin welds have been completed, place the liner channels around the liner plate
periphery. Do not place channels on the edge of the sheet adjacent to a sheet not previously fastened down.
See Figure 1.

6.9 Pins should be located at the centre of the channel slots.

6.10 Place washers over the pins on which the channels have been installed, while ensuring the channels are
not moved. A minimum one (1) inch and maximum four (4) inches should exist between the end of a channel
and any other channel or obstruction. See Figure 1.

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-101-02
Installing Washers and Channels on Insulated Duct Walls
Revision No.:02 Rev. Date: 06/08/2022
Print Date June 14, 2022 Page 3 of 9

6.11 Starting in the centre of the channel, place the modified vice grip over smooth pin, with washer, located
approximately in the centre of channel and tighten vice grip.

6.12 After vice grips are installed on all pins on any one channel (Figure 3) start in the middle of the channel and
hammer the vice grip down “Hard” (Figure 4) so that the washer is tight against the channel. Repeat the
procedure moving from the centre of the channel to the ends, alternating form one side of the centre to the
other.

6.13 When all the washers for a channel have been tightened down, stand on the channel on either side of each
pin. If a gap opens between the washer and the vice grip or washer and channel, the vice grip in that location
needs to be hammered down further until no gap remains.

6.14 When no gap appears, weld the pin to the washer in the gap between the vice grip jaws, both sides. Proceed
with all the washers on that channel. See Figure 3.

6.15 Remove the center vice grip and complete weld around the pin per drawing. Proceed along the channel
alternating from one side of completed pins to the other along the channel length.

6.16 After all washers are welded down on a liner sheet, check that the washers are tight against liner by standing
immediately adjacent to two opposing sides.

6.17 On pins 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 pin and washer and using a sledge hammer, hit the pipe hard a couple
of times to bend the washer down against the liner. 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 liner sheet installation
02 adjacent to a duct wall corner. Place washers over pins that are protruding through the sheet in the center
locations while leaving the perimeter edge holes of the sheet for a later step. Refer to pins 1 and 2 in Figure
1.

7.2 Starting at the threaded pin located approximately in the centre of the sheet 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 liner sheet.

7.4 At the perimeter holes of the liner sheet, a channel will generally be required. Install washers and channels
over the liner sheet edge pins, correctly aligning with channel holes over the pins.

Note: The channels should only be installed on the side adjacent to liner sheets that have already been
fastened down. See Figure 1.

7.5 A nut is then installed and tightened to 25 foot pounds on the pin at approximately the centre of the channel.
The nuts are installed and tightened to the pins on alternate sides of the “centre” pin.

7.6 Once the liner sheet 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-101-02
Installing Washers and Channels on Insulated Duct Walls
Revision No.:02 Rev. Date: 06/08/2022
Print Date June 14, 2022 Page 4 of 9

7.7 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.

7.8 Note that if standing immediately adjacent to opposing sides of washer and a gap is apparent between nut
and washer or washer and liner, 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-101-02
Installing Washers and Channels on Insulated Duct Walls
Revision No.:02 Rev. Date: 06/08/2022
Print Date June 14, 2022 Page 5 of 9

8 FIGURES

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written consent of PROPAK. All printed copies are uncontrolled.
 IST-WI-101-02
Installing Washers and Channels on Insulated Duct Walls
Revision No.:02 Rev. Date: 06/08/2022
Print Date June 14, 2022 Page 6 of 9

Figure 1 – Liner Plate Installation

02

Minimum 1” and
maximum 4” clearance
to adjacent sheet /
channel.

Typical.

Figure 2 – Modified vice-grip

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-101-02
Installing Washers and Channels on Insulated Duct Walls
Revision No.:02 Rev. Date: 06/08/2022
Print Date June 14, 2022 Page 7 of 9

Figure 3 – Multiple vice-grips installed along channel length

Figure 4 – Vice-grip hammer loading

Acceptable
washer gap
shown

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-101-02
Installing Washers and Channels on Insulated Duct Walls
Revision No.:02 Rev. Date: 06/08/2022
Print Date June 14, 2022 Page 8 of 9

Figure 5 – Washer gap check

Figure 6 – 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-101-02
Installing Washers and Channels on Insulated Duct Walls
Revision No.:02 Rev. Date: 06/08/2022
Print Date June 14, 2022 Page 9 of 9

9 REVISION HISTORY
DETAILED DESCRIPTION OF CHANGES

02 06/08/2022 Fixed formatting, added section reference and added note to figure BB AB
01 10/10/2019 Issued for Release JL 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.