Lecture on Travelling water

screen, Trash rack, Coarse

screen & Stop log gate

By P.Teekaraman, Water System

Power Project Division
BGR Energy Systems Ltd
 INDEX

• Definition & Application

• Types

• Main components

• Design parameters

• Design codes

• Operation philosophy

• Material of construction

1
PLANT WATER DIAGRAM FOR RIVER WATER SYSTEM
INTAKE
WATER COOLING
CT MAKEUP WATER SYSTEM

RESERVOIR POST WATER BOILER

TREATMENT PLANT CYCLE
(DM WATER) MAKEUP
CLARIFIED WATER
PRE TREATMENT STORAGE/ SERVICE
PLANT FILTERED WATER WASHING
WATER
STORAGE

DRINKING
POTABLE WATER
PURPOSE
PLANT WATER DIAGRAM FOR SEA WATER SYSTEM

SEA WATER
COOLING
CT MAKEUP WATER SYSTEM

FOREBAY
SEA
WATER PRE TREATMENT
RO STAGE I RO STAGE II
INTAKE PLANT
PUMP
HOUSE
SERVICE
WATER

POTABLE
WATER

BOILER POST WATER

CYCLE TREATMENT PLANT
MAKEUP (DM WATER)
 INTAKE
CHANNEL

FOREBAY

STOP LOG
GATE

TRASH RACK/
COARSE SCREEN

TRAVELLING
WATER
SCREEN

PUMP

PUMP SUMP
TYPICAL ARRANGEMENT OF PUMP HOUSE

PROCESS
 INTAKE
CHANNEL

FOREBAY

STOP LOG
GATE

TRASH RACK/
COARSE SCREEN

TRAVELLING
WATER
SCREEN

PUMP

PUMP SUMP
TRAVELLING WATER SCREEN IN PUMP HOUSE

PROCESS
 DEFINITION & APPLICATION
TRAVELLING WATER SCREEN

A travelling screen is a type of water filtration device that has a

continuously moving mesh screen that is used to catch and
remove debris.

This type of device is usually found in water intake systems in

Thermal power plant, Hydroelectric generators, Petroleum
refineries and Chemical plants.

Travelling screens are used to divert fish, aquatic species and

debris including leaves, sticks, and trash; for the purpose of
preventing damage to cooling water system.
TWS IN A POWER PLANT
 TWS in Power plant

• P&ID for Sea water intake system

• P&ID for Travelling water system

8
 TYPES OF TWS

• Through-Flow Band Screen

• Dual Flow Band Screen

• Centre Flow Band Screen

9
Through-Flow Band Screen

10
 Through-Flow Band Screen

• Mesh is placed perpendicular to the flow direction

• The screening takes place on the front side of the mesh

• It does not require a special civil construction.

• Uniform flow pattern through the screen.

• Minimal head loss (Ex. 50 to 75mmwc).

• Mesh sizes range from 4 to 10 mm

• Flat basket design.

11
Dual Flow Band Screen

12
Dual Flow Band Screen

13
 Dual Flow Band Screen

• Screens are installed parallel to the flow

• Double entry-single exit flow pattern eliminates debris
carryover.
• Utilizes both the ascending and descending sides of the
screen for a large screening area.
• Special civil construction is required for installation
• Head loss will be slightly higher (5%) compare to Through
flow band screen.
• Mesh sizes range from 4 to 10 mm
• Flat basket design
14
Centre Flow Band Screen

15
Centre Flow Band Screen

16
 Centre Flow Band Screen
• Screens are also installed parallel to the flow
• Difference from the dual flow travel band screens is that the
water flows into the center of the screen frame and then out
through the mesh panels
• Single entry double exit eliminates debris carryover.
• Head loss will be slightly higher (5%) compare to Through
flow band screen.
• Mesh sizes range from 0.1 to 10 mm
• Semi circular basket design

17
 Main components of TWS

• Screen wire mesh / Perforated sheet

• Basket

• Spray nozzles

• Embedded parts

• Strainers

• Screen wash pumps

• Valves, piping & instruments

18
Main components of TWS

19
 Typical design parameters : TWS
Sl.No Particulars Units Typical Values
Design / Maximum Flow rate through each 3820 / 130% design
1. screen m3/hr flow

Size of the screen 2200(W)x11000(H)

2.

3. Travelling Screen clear opening mm 10 x 10

Maximum water velocity through screen at

4. minimum water level at maximum flow rate of 0.5 m/sec
screen

Design differential head for Travelling water

5. Screens mwc 2

Maximum head loss across Travelling water mwc 0.075

9.
Screens i.e. (between inlet & outlet)

Screen backwashing/flushing start “ON” Head

10. loss across TWS mWC 0.100
Lever operating
11. Discharge Mechanism mechanism & timer
20
 Design code : TWS
There is no specific product code for Travelling water screens, however vendor is
considering following component codes while designing the TWS.
• IS 2405 (Part I) : Specification for industrial sieves
• IS 2405 (Part II) : Specification for perforated sheets
• IS 9137 : Code for acceptance for centrifugal, mixed flow and axial flow pumps
– Class ‘C’
• BS 9906 : Rotodynamic pumps – Hydraulic performance acceptance tests –
Grades 1 and 2
• PTC 8.2 : Power Test Codes – Centrifugal pumps.
• Hydraulic Institute Standards – ANSI / HIS, latest Edition
• ISO 7919 : Mechanical Vibration of non – reciprocating machines –
Measurement on rotating shaft and evaluation criteria
• ISO 10816 : Mechanical Vibration – Evaluation of machine vibration by
measurements on non – rotating parts
21
Typical Layout for the TWS in PH

22
Typical Layout for the TWS in PH

23
Operation philosophy for the TW screen
Travelling Water Screens (TWS) operated through following

modes of operation from PLC / DDCMIS.

• Manual Mode

• Timer Mode

• Auto Mode thru’ differential level between upstream and

downstream of TWS’s.

24
 Operation philosophy for the TW screen
Manual Mode
• Start push button is pressed/selected
• TWS starts operating on low or high speed as selected
• Continue to run until operator switches it off (irrespective of differential
levels)
Timer Mode
• TWS starts operating on low/high speed (depending upon selection) thru’
timer – at the selected time interval
• Stop after the preset run time.
• Even though the run timer times out, but the differential level of the TWS
has not fallen below “differential level normal” the TWS continue to rotate till
the differential level falls below the preset limit.
25
Operation philosophy for the TW screen
Auto Mode
• On receipt of high differential level signal, the TWS selected in
‘Auto’ mode will start on low speed and rotate until differential level
falls below the preset limit.
• TWS Operation (Slow speed): TWS start on slow speed when it
senses “TWS @ Differential Level High” and shall continue to
operate until “TWS @ Differential Level Normal” is sensed.
• TWS Operation (High Speed): TWS operate on high speed when
“TWS @ Differential Level Very High” is sensed through Level
Transmitter or “TWS @ Differential Level Very Very High” is
sensed through Differential Level Switch.

26
 Factors affecting performance of TWS
Off load condition and natural climatic conditions are mainly affecting the
performance of TWS. This factors are beyond our control.

 Flow much more than what was provided at the time of selection
 Very high water level than what was considered at the time of selection

Other factors affecting the performance of TWS. This factors can be controlled from
our end.

 Improper installation by customer.

 Machine is operated by un-trained personnel.
 O&M manual not made available to the operator.
 No cleaning at regular interval, no refill of the oil, no scheduled preventive
maintenance. Auto-running of the screen bypassed. Running the machine
on manual mode.
 Ultrasonic level sensors missing or damaged.
 Fault in control panel circuits. 27
 TWS
MATERIAL OF CONSTRUCTION

• Stainless steel 304

• Stainless steel 316

• FRP

• Duplex SS 2205 UNS31803

• Super duplex

28
TRAVELLING WATER SCREENS
TRAVELLING WATER SCREENS
TRAVELLING WATER SCREENS
 INTAKE
CHANNEL

FOREBAY

STOP LOG
GATE

TRASH RACK/
COARSE SCREEN

TRAVELLING
WATER
SCREEN

PUMP

PUMP SUMP
TRASH RACK / COARSE SCREEN IN PUMP HOUSE

PROCESS
 DEFINITION & APPLICATION
TRASH RACK / COARSE SCREEN

Trash rack / Coarse screen are used for removal / screening of

floating waste coming with water in pumping stations from river
(or) sea.

This type of device is usually found in water intake systems in

Thermal power plant, petroleum refineries and chemical
plants.
 Trash rack
• Bars are used to stop the floating debris.

• It can be fixed or removable

• The thickness of each bar is 10mm and pitch distance

will be 50mm
Trash rack
 Trash rack
Trash rack could be in Single piece or in Multiple pieces

• When the height of water is very high, provision of Single-piece Trash

rack becomes difficult due to its size and weight. In that case Multi-
piece trash racks are used.

• Multi-piece trash racks comprise of number of racks of smaller

heights stacked over one another covering the full depth of water.
Generally the each panel height is 1.8mtr to 2.5mtr (depends upon
vendor design).

Trash racks are to be lifted up to platform using suitable lifting devices

for removing the trash. Before removal from its position, Sluice gates /
Stop-logs should be lowered to shut off the flow to pump sump.

After cleaning, Trash rack is lowered back in to its position and then
Stop-logs are removed to allow only screened water flow in to the pump
sump.
Typical Trash rack / Coarse screen
Trash rack
 Types of Trash rack

• Removable type trash rack

• Fixed type trash rack

39
 Types of Trash rack
Removable type trash rack

In general this type of trash rack is used for all power plant. It
is removed from sump with the help of hoist and lifting beam
arrangement above the operating floor. Debris will be
removed from trash rack with the help of potable submersible
pump spray nozzles (or) Manually cleaned.

40
 Types of Trash rack
Fixed type trash rack

In general this type of trash rack is used for all Intake

Canal/Dam. It is fixed in the sump. Debris will be accumulated
near the trash bars. Then it will be removed from trash rack
with the help of Trash rack cleaning machine (TRCM) or Grab
cleaner.

41
Cleaning the Trash rack

42
 Main components of Trash rack

• Bar rack

• Side guide-cum-track

• Embedded parts

• Frame

• Fasteners

43
 Typical design parameters : Trash rack
Type Removable type

Design Standard IS: 11388

Nos. Three (3)

Quantity of Trash rack

No. of sumps/compartments which require embedment (Both Nos. Three (3) Nos. at upstream of pumps
first stage and second stage) and Three (3) for future bays
m3/hr 3820
Design flow rate

m3/hr 5630
Maximum flow rate

mm x mm 2500 (W) x 11000 (H)

Size of the Trash rack (width x Height)

mm x mm 2200 (W) x 11000 (H)

Size of the opening provided in the sump (width x Height)

mm x mm 50 x 50 and 10
Pitch opening/ clear opening of wire mesh and bar thickness
12 Gauge
Diameter of wire mesh

mWC 1
Design differential head

deg 80
Inclination angle

Maximum head loss across Trash rack i.e. (between inlet &
mwc 0.050
outlet)

44
 Design code : Trash rack
While designing the Trash rack following codes to be

considered.

• IS 11388 : Recommendations for design of trash racks for

intakes

45
Typical Layout for the Trash rack

Layout of Trash rack along with TRCM

46
Operation philosophy for the Trash rack
Trash rack is fixed type. It shall be cleaned with TRCM.

Hence following modes of operation from PLC is provided.

• Manual Mode

• Timer Mode

• Auto Mode thru’ differential level between upstream and

downstream of Trash rack.

47
Operation philosophy for the Trash rack
If the Trash rack is removable type. It shall be lifted with the

help of lifting beam & hoist above operating floor. Then it is

cleaned with help of potable submersible pump spray nozzles

(or) Manually cleaned.

48
 MOC : Trash rack
The material of Trash rack (bar, side guide-cum-track,

Embedment's, Frame & Mechanical fasteners) shall be as

follows :-

• Carbon steel

• Stainless steel 304 / 316

• Duplex SS 2205 UNS31803

• Super duplex

49
TRASH RACK CLEANING MACHINE IN INTAKE CANAL
TRASH RACK CLEANING MACHINE
 TRCM working

TRCM working video clip

Trash cleaning

Grab cleaner
 Coarse Screen
Raw water, Waste water or effluent invariably contains lot of floating waste, debris etc
and it is very essential that they are removed at the first instance. The process of
removal of this floating waste is called screening. The equipment used for this
process is called screen.

Screening-out of waste and debris maintains efficiency of equipment’s installed in the

downstream and reduces frequent breakdowns. Hence selection of the best
screening system for a particular project is an important step.

Important factors guiding selection of screening equipment are:

• Size of opening to be provided in the screen.

• Installation particulars especially the depth of the channel.

• Other criteria may include capital cost of equipment, capital cost of civil works,
operating cost of equipment and equipment life expectation.
Coarse Screen
Coarse Screen
 TYPES OF SCREENS

• Based on opening size: Coarse, Medium & Fine

• Based on cleaning method: Manual & Water jet

• Based on configuration: Bar screens & Mesh screens

• Based on screen surface: Fixed & Moving

57
 TYPES OF SCREENS
Coarse Screen
It is meant to protect pumps, valves, pipe lines, impellers and other related
equipment. It is installed at the intake of waste water before pumping,
primary settling or grit chamber and is made up of a grid of rods or bars.
Screen opening size 6 to 150mm.
Plastic bottles, cans, cloths, plastic bags, napkins, household wastes,
weeds, shrubs etc to be removed.

Fine Screen
These screens are located behind coarse. These screens are meant to
prevent entry of small debris such as sticks, barks, leaves, fishes etc.
Screen opening size less than 6mm.
Plastic pouches, fibrous vegitable waste, shredded and torn cloths,
condoms, grass and various material , that passes through the coarse
screen to be removed.

58
 TYPES OF SCREENS
Manual Screen
Cleaning is done by manually.
Water jet Screen
Cleaning is done by through water jet.
Bar Screen
Trash bar is used in the screen.
Mesh Screen
Wire mesh is used in the screen.
Fixed Screen
Screen is fixed in the pump sump.
Moving Screen
Screen is removable from pump sump.
59
TYPES OF SCREENS

60
TYPES OF SCREENS

61
 TYPES OF SCREENS
Rotary drum type screen Hyperbole static screen

62
Typical design parameters : Coarse screen
Particulars Units Typical values
Coarse screen
Type of Screen
IS: 2405
Design Standard
38905
Design flow rate m3/hr
50576.5
Maximum flow rate m3/hr

Size of the coarse screens (width x Height) mm x mm 7300 (W) x 8200 (H)

Size of the opening provided in the sump (width x Height) mm x mm 6700 (W) x 8200 (H)

Pitch opening/ clear opening of wire mesh mm x mm 10 x 10

1
Design differential head mWC
12 Gauge
Diameter of wire mesh
Channel
Location
0.5m/sec
Approach velocity

0.050
Maximum head loss across screen mWC

63
Main components of Coarse screen

• Screen wire mesh

• Side guide-cum-track

• Embedded parts

• Frame

• Fasteners

64
 Design code : Coarse screen
While designing the Coarse screen following codes to be

considered.

• IS 2405 (Part 1) : Specification for industrial sieves

• IS 2405 (Part II) : Specification for perforated sheets

65
 Typical Layout for the Coarse screen

Coarse screen GA drawing

66
 Operation philosophy for the Coarse screen

Mostly the coarse screen is removable type. It shall be lifted

with the help of lifting beam & hoist above operating floor.

Then it is cleaned with help of potable submersible pump

spray nozzles (or) manual cleaning.

67
 Operation philosophy for the Coarse screen
Problems in Automatic screens

Automatic screens does not required operated to run the screen, but it
definitely calls for regular supervision of operation. Power failure is a
common phenomenon particularly in India and during the period of non-
availability of power there is possibility of excessive accumulation of waste
on to the screen field or during normal operation of screen, waste of very big
size and shape may hit the screen field and block the screen field.

This kind of situation is more predominant in case of screens installed in

take / pumping stations. In such a situation it is very essential that such
wastes are removed manually before permanent damage occurs to the
machine.

68
MOC : Coarse Screen

69
 INTAKE
CHANNEL

FOREBAY

STOP LOG
GATE

TRASH RACK/
COARSE SCREEN

TRAVELLING
WATER
SCREEN

PUMP
STOP LOG GATE IN PUMP HOUSE

PUMP SUMP

PROCESS
 DEFINITION & APPLICATION
STOP LOG GATE

Stop logs are used for isolation duties in open channel. Stoplogs
can be of single piece (or) multiple piece stacked together to
achieve the desired total height.

Normally used to isolate equipment's such as pumps & screens

during maintenance

This type of device is usually found in water intake systems in

Thermal power plant, petroleum refineries and chemical plants.
DEFINITION & APPLICATION
STOP LOG GATE
 TYPES OF STOP LOG GATES

• Bulk head gates (or) Wheel gates (or) High head SLG

• Medium/Low head (or) Slide stop log gates

• Emergency (or) Guards gates

• Regulating gates

73
 TYPES OF STOP LOG GATES
Bulk head gates

It is a singular structures that provide isolation, effectively

shutting off flow for maintenance.

Features

• Roller guides to allow Bulkheads to be operated under flow

conditions.

• Top seals available.

• Designed to withstand 30m & above.

• Custom designed and fabricated to suit any size or shaped

74
 TYPES OF STOP LOG GATES
Bulk head gates (or) Wheel gates (or) High head SLG

75
Types of Slide stop log gates

Medium head stop log gates

• Designed to withstand 15m to 30m .

Low head stop log gates

• Designed to withstand upto 15m.

76
 Types of Slide stop log gates
Emergency (or) Guards gates

• Designed to be closed under unbalanced head

• Opening of gates can be done under balanced (or)

unbalanced head.

• They are kept either fully open (or) fully closed.

Regulating gates

• Used for regulating water flows

• Operated under unbalanced head condition.

• Suitable for small size outlets

77
78
Typical design parameters: Stop log gates
Particulars Unit Typical values
7300 (W) x 4500 (H) – (0.5 m
Size of the stop log gates (Width x Height) mm x mm
above breast wall is considered)
Size of the opening provided in the sump (width x 6700 (W) x 4000 (H)
mm x mm
Height)
2 Nos.
Quantity of stop log gates Nos.
Circulating sea water (refer
Quality of service fluid specification)
38905
Design flow M3/hr
Maximum flow M3/hr 50508
No. of pump bays/compartments which required guides /
Nos.
embedment’s (Both first stage and second stage) 3 Nos.
Design and construction standard IS – 5620
10m
Minimum lift required for handling stop log gates/screens m

Qty. of Lifting beam required for handling CW sump stop One (1)
Nos.
log gates/Coarse screens
Semi-gantry capacity provided in Tons tons 5T

79
Main components of Stop log gate

• Gate Leaf

• Embedded parts

• Equalizing valve (if required)

• Fasteners

80
 Main components of Stop log gate
Gate Leaf
It is a rigid structure consisting of skin plate. The skin plate
may be upstream or downstream of gate. Upstream skin plate
avoid accumulation of debris inside the gate leaf.
Embedded parts
Main functions are :-
• Transmit water load on the gate leaf to supporting structure
(Concrete)
• To guide the gate leaf during operation
• To provide sealing surface
81
Main components of Stop log gate

82
Main components of Stop log gate

83
Main components of Stop log gate

Equalizing valve
Closed condition Open condition

84
Main components of Stop log gate

Sealing of SLG

85
 Design code : Stop log gate
While designing the Stop log gate following code to be

considered.

• IS 5620 : Recommendations for Structural Design Criteria

for Low Head Slide Gates

• IS 9439 : Recommendations for Structural Design of

Medium and High Head Slide Gates

• DIN 19704 (1976) : Principles for computation for steel

hydraulic plant 86
 Operation philosophy for the Stop log gate

Generally the Stop log gate is removable type. It shall be

lifted with the help of lifting beam & hoist above operating

floor. Then it is cleaned with help of potable submersible

pump spray nozzles (or) manual cleaning.

87
Operation philosophy for the Stop log gate
LIFTING BEAM

88
 MOC : Stop log gate
The material of Stop log gate (Gate leaf, Gate frame, Seal

plates, seal seats & guides) shall be as follows :-

• Cast Iron

• Stainless steel

• Duplex SS 2205 UNS31803

• Super duplex

89
STOP LOG GATES
STOP LOG GATES
THANK YOU