Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036

Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011

Contract Number: A5MU Page 1 of 13
Revision 1

SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

This specification has been revised as indicated below and described in the revision record on the
following page. Please destroy all previous revisions.

Revision Date Originator's Reviewed/Checked By Pages

No. Name & Initials Name & Initials
A 6/16/10 L. STREEB T. WOOD ALL
0 10/15/10 L. STREEB T.WOOD ALL
1 3/8/11 L. STREEB T. WOOD ALL

APPROVALS SIGNATURES DATE

Lead Engineer
Engineering Manager:
Client Approval:

ISSUED FOR : Construction X Other ISSUED APPROVED

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011
Contract Number: A5MU Page 2 of 13
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SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

Record of Revisions
Revision Date Description
No.

A 6/16/10 CLIENT REVIEW - TOC

0 10/15/10 ISSUED FOR REVIEW/APPROVAL - SPECIFICATION

1 3/8/11 ISSUED APPROVED

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011
Contract Number: A5MU Page 3 of 13
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SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

TABLE OF CONTENTS
1 SCOPE………………………………………………………………….……………….….……….…….5

2 REFERENCES…………………………………………………………….…………….……………….5

2.1 ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS.………….……………..…….….5

2.2 AWS (AMERICAN WELDING SOCIETY).……………………………………………….……………5

2.3 SSPC (STEEL STRUCTURES PAINTING COUNCIL)…….……………..………………………….5

2.4 OSHA (OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION)………..…….….……..…5

3 GENERAL …………………..…………………………………………………………….……..…...…..6

3.3 DOCUMENTATION.………..…………………………………………………………..….……...….....6

3.4 PERFORMANCE.…………….……………………………………………………….…….…….......…6

4 GENERAL REQUIREMENTS……………….……………………………………….…….……….…..6

5 TECHNICAL REQUIREMENTS……..……………………………….…………….…………….…….6

5.3 DRIVE UNIT……………….………………..….……………………………………...…………….......7

5.4 HEAD SHAFT ASSEMBLY…….….……….…………………………………….……….……..…......7

5.5 SCREEN….……………….………………..….……………………………………..…..………..........8

5.6 HEAD TERMINAL ENCLOSURE AND SPRAY SYSTEM….…….….………………....………......8

5.7 FRAME AND GUIDEWAYS…………..…..….………………………..……………..……..……........9

6 OPTIONS…………………………………………………………………………….………….……......9

6.1 DIFFERENTIAL HEAD CONTROL SYSTEM (OPTION)………….…………….………….….........9

6.2 SPRAY SYSTEM PUMP (OPTION)……….………..………………….………….……….…….......10

7 PAINTING……………………………..………………………………..…….…….……….…………...11

8 WELDING………………………..…………………………………….…………….…….…………….11

9 SPARE PARTS………………………….…………………….……………………...…………….......11
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011
Contract Number: A5MU Page 4 of 13
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SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

10 NOISE……..………………………….………………….……………………………….…..……….....11

11 LUBRICATION………..…………………………….……………………………………………….......11

12 INSPECTION AND TESTS…………..………………………………………………………………...11

12.1 INSPECTION…………………………..………………………………………………………………...11

12.2 TESTS…………………………………..………………………………………………………………...12

13 PREPARATION FOR SHIPMENT…….…..………………………………………….………………..12

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011
Contract Number: A5MU Page 5 of 13
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SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

1 SCOPE

This specification prescribes the general requirements for Traveling Water Screens. The
requirements outlined herein supplement the Data sheet - Traveling Water Screens, on which the
operating conditions and special requirements are listed in detail for each system. If conflicts
exist, the data sheet shall govern.

2 REFERENCES
The publications listed below form part of this specification. Each publication shall be the latest
revision and addendum in effect on the date of the contract award. Except as modified by the
requirements specified herein or the details of the drawings, Work included in this specification
shall conform to the applicable provisions of these publications.

2.1 ASME (American Society of Mechanical Engineers)

ASME B1.20.1 Pipe Threads, General Purpose (Inch)

ASME B16.5 Pipe Flanges and Flanged Fittings NPS ½ through NPS 24 Metric/Inch
Standard

ASME B30.20 Below the Hook Lifting Devices

ASME B31.3 Process Piping

2.2 AWS (American Welding Society)

AWS A2.4 Standard Symbols for Welding, Brazing and Nondestructive Examination

AWS A3.0 Standard Welding Terms and Definitions

AWS D1.1/D1.1M Structural Welding Code – Steel

2.3 SSPC (Steel Structures Painting Council)

SSPC SP6 Commercial Blast Cleaning

2.4 OSHA (Occupational Safety and health Administration)

29CFR1910 General Industry

Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011
Contract Number: A5MU Page 6 of 13
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SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

3 GENERAL

3.1 The Traveling Water Screens shall provide primary cleaning of water used for the plant's
once-through cooling system. A fixed bar grid shall be provided upstream of the screen,
and pumps shall be located downstream of the screens.

3.2 Utilities shall be available as described on the Traveling Water Screens Data sheet.

3.3 Documentation

Supplier shall supply the type and quantity of drawings and documentation for Purchaser’s
authorization or information as listed on the Supplier Drawing and Data Commitment Form.

3.4 Performance

3.4.1 The Traveling Water Screens shall be designed to screen the water at the
specified rate and conditions as indicated on the data sheet.

3.4.2 Materials of construction shall be suitable for the specified type of water service
and shall conform to the data sheet requirements.

3.4.3 Supplier shall guarantee the traveling screen to meet the requirements and load
as specified on the data sheet.
4 GENERAL REQUIREMENTS
4.1 The Traveling Water Screens shall be Supplier's standard design, modified as required to
comply with this specification. Major equipment shall be of proven design with a minimum
of 2 years of successful operation in equal to or more severe than design operating
conditions, as outlined in the Traveling Water Screens Data sheet.

4.2 Maximum shop prefabrication is required to minimize field erection labor. Supplier shall
provide specific details of field tasks required to erect the equipment.

4.3 Equipment and piping shall be arranged so that when installed, all external and internal
components requiring manipulation, observation, and maintenance shall be readily
accessible and safe to operating and maintenance personnel.

5 TECHNICAL REQUIREMENTS
5.1 The Traveling Water Screens shall be of the direct flow-through type with vertical single
post frames. Screen trays shall be mounted on 2 strands of continuous chain and have
articulated overlapping frames so that openings are never greater than the specified screen
opening.

5.2 A spray system shall be furnished to wash solids from the ascending side of passing screen
baskets into a trough for disposal, and flushes away the solid matter to the trash basket.
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011
Contract Number: A5MU Page 7 of 13
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SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

The spray water drains back into the sump. Spray nozzles shall deliver overlapping water
sprays across the entire back of the screen trays, thereby assuring complete debris
removal.

5.3 Drive Unit

5.3.1 Screen drive systems shall be designed to overcome all inertial, frictional, and
operational loads from starting with a 1.52 m (5'-0") differential head at maximum
water level.

5.3.2 The drive shall be sized to operate the screen continuously with a 0.61m (2'-0")
differential head and to start the screen with a 0.76m (2’-6”) differential head at
maximum water level. The drive shall be located where it is readily accessible.
The supporting frame shall be sturdy and compact.

5.3.3 The reduction gear shall be helical type and shall be designed for 1.5 times the
NEMA rated stalling torque. The gear reducer shall be mounted outside of the
screen head enclosure.

5.3.4 A chain drive shall transmit power from the speed reducer to the screen head
shaft assembly. The chain shall be standard heavy-duty series roller chain rated
for 1.5 times the full NEMA rated stalling torque. The chain shall be oil bath
lubricated within a dust-tight chain guard. Chain(s) shall be suitable for operation
in the water specified on the data sheet.

5.3.5 A fluid coupling shall be furnished to protect equipment from overload. Units
employing a shear pin arrangement shall not be acceptable.

5.4 Head Shaft Assembly

5.4.1 The head shaft assembly shall be designed to resist, without damage, the full
NEMA rated stall torque of the drive when the stalling load is applied to the main
screen chain on the side opposite the drive.

5.4.2 Support shall be by adjustable bearing blocks with grease lubricated bushings.
Chain tensioning take-up screws shall be fitted with self-adjusting nuts and thrust
bearings.

5.4.3 Each head sprocket shall be designed with renewable sprocket tooth inserts.
Hardened inserts shall be bolted to the tooth body and easily replaceable without
cutting the chain or removing the head shaft assembly from the screen. To
ensure proper fit, the seats for the inserts shall be machined and the inserts shall
be machine ground. Inserts shall be held in place by machine bolts.
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011
Contract Number: A5MU Page 8 of 13
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SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

5.5 Screen

5.5.1 The screen materials of construction and screen cloth opening and wire size
shall be as specified on the Data sheet.

5.5.2 Screen panel sections shall be fabricated with a rigid frame. The screen fabric
shall be secured in place by clamping bars and fasteners.

5.5.3 The lower edge of each screen panel assembly shall provide a shelf for lifting
trash. Shelf shall extend the full width of the screen panel.

5.6 Head Terminal Enclosure and Spray System

5.6.1 The head end of the screen shall be equipped with spray pipes and adjustable,
non-clogging, flat type, spray nozzles to project fan-shaped, overlapping sprays
across entire width of screen panels. Spray system shall include shut off valve.

5.6.2 The spray orifices shall have round openings, leaving the pipe smooth on the
inside for easy cleaning. The screen panels shall be washed on the ascending
run.

5.6.3 The spray water feed pipe shall extend beyond the screen housing and shall
terminate in a 150# RF flange.

5.6.4 All piping shall be designed, fabricated, and tested in accordance with the
requirements of ASME B31.3. Piping materials shall be as specified on the data
sheet.

5.6.5 Flanges shall be in accordance with ASME B16.5. Flange bolt holes shall
straddle vertical centerline.

5.6.6 Threaded connections shall be in accordance with ASME B1.20.1.

5.6.7 Cast iron piping or fitting materials shall not be used.

5.6.8 Pipe sizes of 1-1/4, 2- 1/2, 3- 1/2, and 5 inches shall not be used.

5.6.9 The head sprockets, spray nozzles, and refuse trough shall be enclosed by a
splash proof housing. The housing shall be furnished with inspection ports in the
rear lower section so that the screen trays can be seen at all times.

5.6.10 Inspection doors in both ends of the head enclosure shall be provided to permit
the operator to inspect the spray nozzles and afford access to the pipe plug for
cleaning the supply pipe. Inspection doors shall be gasketed for sealing and
equipped with stainless steel hinges and locks.
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011
Contract Number: A5MU Page 9 of 13
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SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

5.6.11 The housing shall be furnished with a fiberglass discharge chute, extending the
length of the housing, with an approximately 1.22 m (4'-0") extension beyond the
screen head section, at an angle of 45 degrees.

5.6.12 The splash proof housing shall be designed in such a way as to permit ready
removal in the event maintenance access to the screen machinery is required.

5.7 Frame and Guideways

5.7.1 Supplier shall furnish standard length, cast iron guideways for Purchaser’s
embedment into concrete water intake structures.

5.7.2 The frame shall be of heavy-duty construction. It shall include the conventional
features such as stiffeners, bracing, seals, guide track for the carrier chain,
mountings for drive and idler shafts, and be of 2-post construction.

5.7.3 The head frame shall be provided with lifting yokes with adequate size and
capacity for attaching a hoist to lift the screen assembly from its position.

5.7.4 The intermediate and bottom frame sections shall have provisions for lifting and
support during installation or future removal.

5.7.5 Screen frame sealing guards shall be furnished to protect the chain and
renewable chain tracks on the ascending run.

5.7.6 The boot section shall provide for a minimum running clearance, incorporating a
fixed shallow type boot plate, curved to ensure a positive seal with articulating
baskets.

6 OPTIONS

6.1 Differential Head Control System (Option)

6.1.1 A wall-mounted or free-standing differential head control system shall be

furnished to operate the traveling water screen automatically when the differential
head exceeds a predetermined setting. Head control system shall be in
accordance with the data sheet.

6.1.2 The head control system shall be complete and self-contained unit, only requiring
external connections for air and electrical power. The control panel enclosure
shall be as specified in the data sheet.

6.1.3 Instruments shall be tagged with numbers assigned by the Purchaser. Unless
otherwise specified, instrument manufacturer/supplier selections are subject to
Purchaser approval.
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011
Contract Number: A5MU Page 10 of 13
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SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

6.1.4 Representation of instrumentation on all submittals shall be in accordance with

ISA 5. I.

6.1.5 Supplier shall furnish all specified controls, instruments and devices required for
intended operation of the system.

6.1.6 Supplier shall be responsible for the selection of instrument operating range,
pressure rating, set point, and materials of construction based on process
conditions and locations specified in the data sheet.

6.1.7 The head control system shall include a program timer, hand off-auto selector
switch, air flow control valves and flow meters, pressure gauges, differential
pressure instruments, and all other solenoids, alarms, terminal strips, indicator
lights, and transformers required to make a complete and workable system.

6.1.8 When the selector switch is in the "Auto" position and the preset differential
pressure has been exceeded, the head control shall start the spray water pump.
When spray manifold is pressurized, the screen drive motor shall automatically
start and continue operating until all screens have been cleaned.

6.2 Spray System Pump (Option)

6.2.1 Supplier shall furnish a grade-mounted vertical pump with motor, suitable for
outdoor installation, to provide a sufficient volume of water for the traveling water
screen spray system.

6.2.2 The maximum allowable pump shaft bearing span shall be 1.22 m (4 feet).

6.2.3 Motors shall comply with Marafiq Motor specification(s).

6.2.4 Motor starter and controls shall be furnished by the Purchaser.

6.2.5 Pump outlet shall terminate in a 150# RF flanged connection. Piping between
pump and water screen spray header shall be by Purchaser.

6.2.6 Wiring between starter, pump and control panel shall be by Purchaser.
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011
Contract Number: A5MU Page 11 of 13
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SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

7 PAINTING

All components other than those made of stainless steel, monel, or aluminum-bronze shall be
primed and finished with Supplier's standard paint. Drive unit and optional pump shall be
manufacturer’s standard paint.

8 WELDING

All structural welding shall be in accordance with AWS D1.1/D1.1M. Welding symbols, terms and
definitions shall be in accordance with AWS A2.4 and A3.0.

9 SPARE PARTS

Supplier shall provide a unit-priced list of recommended spare parts for start-up / commissioning
and 1 year of operation.

10 NOISE

The traveling water screen and pump shall meet not exceed the noise limit of 85 dBA at a distance
of 1m (3 feet). Noise limits shall meet the requirements of the Marafiq Sound Control Specification.

11 LUBRICATION

Supplier shall provide a list of recommended lubrication procedures and compounds for proper
operation and maintenance of the traveling water screen and auxiliary equipment.

12 INSPECTION AND TESTS

12.1 Inspection

12.1.1 Supplier shall furnish the Purchaser copies of the Supplier’s inspection and
quality control plan. Hold points and witness points shall be agreed to.

12.1.2 Materials and workmanship shall be subject to inspection by the Purchaser in the
Supplier’s shop.

12.1.3 The Purchaser’s inspector will check, as a minimum, equipment components,

tagging, critical dimensions, connection sizes and locations, and quality of
workmanship against certified drawings, data, and purchase order documents.
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011
Contract Number: A5MU Page 12 of 13
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SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

12.2 Tests

12.2.1 NDE

Any lifting appurtenance welds shall be dye penetrant examined.

12.2.2 Functional Test

A functional test shall be performed for all instruments and controls, in addition to an
electrical continuity check, before shipping.

12.2.3 Pressure Test

All piping shall be tested in accordance with ASME B31.3.

13 PREPARATION FOR SHIPMENT

Supplier shall be solely responsible for providing adequate preparation for shipment. Preparation
will be subject to inspection and rejection by the Purchaser’s inspector. Minimum preparation for
shipment shall be as described in the following paragraphs.

13.1 Adequate protection shall be provided against mechanical damage and atmospheric
corrosion in transit, and for at least six months outdoor storage at jobsite prior to installation.

13.2 Shipping saddles, bracing, supports, and rigging connections shall be provided to prevent
damage during shipment, lifting, or unloading.

13.3 If applicable, flange faces, other than those furnished with permanent blinds, shall be
covered with 12.7 mm (1/2 inch) thick wood, wood fiber, 3.175 mm (1/8 inch) thick steel
plate, or heavy duty plastic flange protectors. Covers shall be no smaller than the flange
O.D., and secured with a minimum of four bolts. Where wood, wood fiber, or metal covers
are used, a plastic sheet shall be placed between the coated flange and cover for additional
protection.

13.4 Bearings and seal assemblies shall be fully protected from the entry of moisture and dirt.

13.5 Female threaded connections shall be plugged with solid metal pipe plugs, and male
threaded connections shall be protected with full metal pipe caps of the same material as
the piping.

13.6 Exposed unpainted surfaces, including bolting, shall be given a heavy coating of rust
inhibiting compound.

13.7 Separate, loose, and spare parts shall be completely boxed. All pieces of equipment and
spare parts shall be identified by item number and service and marked with Purchaser’s
Power and Water Utility Company for Jubail and Yanbu (MARAFIQ) Specification MQ-SP-M-4036
Project Name: MARAFIQ SPEC DEVELOPMENT Date: 08 Mar 2011
Contract Number: A5MU Page 13 of 13
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SPECIFICATION – WATER INTAKE SYSTEMS – TRAVELING WATER SCREENS

order number, item number, and weight both inside and outside of each individual package
or container. A packing list must be sent to Purchaser prior to shipment.

13.8 One complete set of installation, operation, and maintenance instructions specific to the
equipment being furnished shall be packed in the boxes or crates and shipped with the
equipment.

13.9 Any items which can be damaged by water shall be securely wrapped in waterproof paper
or plastic before being placed in wooden crates.

13.10 Equipment or items containing insulating oils, other oils, solutions, or other fluids shall be
prominently tagged at openings to indicate the nature of the contents, shipping and storage
precaution and an MSDS shall accompany the equipment or items. An MSDS for the
different fluids shall be provided to purchaser prior to shipment.

13.11 Equipment tagging and marking shall conform to the following requirements:

13.11.1 All equipment shall be piece marked and electrical terminals shall be coded to
facilitate field erection.

13.11.2 Instruments shall be tagged with the instrument tag numbers as identified by the
Purchaser on Supplier’s drawings.

13.11.3 In addition to the Supplier’s standard identification, tags shall be furnished to

show the service, Purchaser’s item number, and Purchaser’s order number for
each tag item listed on the Purchase Order.

13.11.4 Instrument and equipment tags shall be impression stamped stainless steel with
4.76 mm (3/16 inch) (minimum) characters and permanently mounted with
stainless steel drive screws or 16 gage (minimum) wire.

13.11.5 Interconnecting piping that will be shipped loose shall be prefabricated and shop
fitted. All such piping shall be match marked prior to dismantling and shipment.

END OF SPECIFICATION