Copyright 2017 TALLEMENCO PTY LTD
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About the Presenter
River Murray to Mount Lofty Ranges – 420m lift
Evaluating pump and pipeline
performance with SA Water for 20
years.
Testing Waikerie CIT PS 2017
Photos: R Welke
Dry year, 90% water pumped from River Murray
4 major pumping systems
Approx 130,000 kW
$millions/annum pumping costs
Tested every 2 years
Over 1000 pump tests
Copyright 2017 TALLEMENCO PTY LTD
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About the Presenter
Pump Testing/Commissioning
MBO No 3 PS 1973
Eg, Murray Bridge –
Onkaparinga Pumps 1973
 3 Pumping Stations,
9 pumps, ≈ 43,000 kW TOTAL
 All pumps All 316SS
 Tested in dedicated pipework.
 Typically 90% pump efficiency
 Corrosion issues.
Copyright 2017 TALLEMENCO PTY LTD
Photo: R Welke
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About the Presenter
Friction
testing
M/W P/L
Pipeline Friction testing
Photos: R Welke
 From largest (1.8m) to smallest
(80mm) pipeline, (“C” Values)
Mannum - Adelaide No.3 PS
 Determine maintenance policy
 Chlorination/pigging/rodding
 Pumping economics
Corroded cast iron pipe. Photo: R Welke
Copyright 2017 TALLEMENCO PTY LTD
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About the Presenter
Defining moment, 2000
“There’s a wheel
barrow in my
Pipeline”
 10 km of 450NB PVC
 Pumps reduced output
 Pipeline friction test, 2000
 Willunga Basin Water Co
Photos: R Welke
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Combine “Hazen & Williams” and “Darcy Weisbach Friction factor”
Graph of “Pipe Bore Roughness” to “C” value
Pipeline Friction
 Reduction of 10% pipe
efficiency (C=135) due
to only 0.1mm of pipe
wall roughness.
80NB to 200NB PVC Class 12
Hazen-Williams "C" Value
160.0
150.0
80NB
140.0
100NB
130.0
150NB
120.0
200NB
110.0
100.0
0
0.1
0.2
0.3
0.4
Bore Roughness - mm
0.5
 This level of roughness
cannot be seen with
naked eye.
 Need to quadruple
bore roughness for
next 10% efficiency
loss (C=120)
Chart: R Welke
Copyright 2017 TALLEMENCO PTY LTD
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Hydroponic lettuce farm
3xPhotos:
R Welke
Pumping Energy Efficiency Audits
 identified > $503,000 annual elect savings (since 2012)
 As much energy efficiency losses in pipes (hydraulics)
as in pumps
Cabbage farm
Pasture farm
Photo: R Vardy
Copyright 2017 TALLEMENCO PTY LTD
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Tariff – locked in by
energy companies
OR use solar
How is electric pumping costed ?
$$/yr*
=
2.73 x
metre head x c/kWh x ML/yr
motor ɳ x pump ɳ
Motor
efficiency
fixed
Pump efficiency
Worn OR
off-BEP
Pump less water –
a) scheduling
b) Soil moisture
monitoring
Elevation
Filter head loss
Main line head loss
Laterals head loss
Layflat hose head loss
Emitter head loss
Residual head
Testing pumps
*Refer www.talle.biz/data.html
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Where can energy be saved?
Pump efficiency
Hydraulic efficiency
Typically < 50%
Recoverable
energy losses
Excess Friction losses + excess residual
Typically > 50% recoverable energy losses
Motor efficiency
Pump efficiency
Excess residual head
Total
Pumped
Head
Emitters
friction loss controllable by
design and maintenance
Friction
Lift (fixed)
Copyright 2017 TALLEMENCO PTY LTD
Mains
Submains
Pipe ageing
Pump suction
Valves
Filters
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How are energy savings measured?
Head
Pump efficiency
Flow
Power
PUMP TEST
(to AS/NZ 3598.2 Type 2
RPM
Time:
Cost:
Hydraulic efficiency
Friction
Residual
½ day – 5 days
$1,000 – $20,000
+ Report
HYDRAULIC TEST
Time:
Cost:
1 - 2 days
$2500-$5000
+ Report
Risk depends on spend level
How is the risk mitigated?
Copyright 2017 TALLEMENCO PTY LTD
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IPEEAT: 2015: Irrigation Pumping Energy Efficiency Assessment Tool
Divides Irrigation into 8 distinct hydraulic models:
CP/LM, Boom,
Gun
Knocker, Rotor,
Drip, spray
Flood
Pipe & Riser
Transfer
Marine
Each type has a unique hydraulic signature
IPEEAT assesses overall pumping energy efficiency considering both pumping
efficiency and hydraulic efficiency by comparing existing on farm
performance with a similar type irrigation system built to best practice
design in its class
Copyright 2017 TALLEMENCO PTY LTD
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IPEEATproLP: 2017
Irrigation Pumping Energy Efficiency
Assessment Tool - Professional (Long Pipe)
1) Calculates Pump Efficiency
a) Evaluates peak flow efficiency
b) Evaluates annual demand efficiency
2) Calculates Hydraulic Efficiency (rising main)
(Needs to be tested at Peak Irrigation Flow)
3) Calculates Carbon Emissions (tonnes/annum)


Suited to long or short rising mains
IPEEATproLP assesses both pumping
efficiency and hydraulic efficiency by
comparing existing on farm performance
with a similar type pumping and pipeline
system built to best practice design
Copyright 2017 TALLEMENCO PTY LTD
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Case Study 1: Lateral Move (2014)
Emitter type –
LM
Defining moment, 2000
Residual Pressure
above nozzle - kPa
End nozzle
Layflat
Static Head,
metres
No filter
Surface pump
River/dam




140 ML /yr
$12,800/yr
24c/kWh. ave
84m pumped head
Belt
drive
Water
level
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Component.
Pump effy
Elevation m
Residual head m
Sum of head
components
$$/ML annual
pumping cost
Case Study 1: Lateral Move 2014
(IPEEAT)
Measured
65%
6m
15m
84m
91
Expected
75%
6m
15m
48m
45
Major findings:
 mainline C=80
 pump effy 65%
Potential annual savings $6,818
Justifies pumping energy audit
Copyright 2017 TALLEMENCO PTY LTD
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Component.
Pump effy
Elevation m
Residual head m
Sum of head
components
$$/ML annual
pumping cost
Case Study 1: Lateral Move
(IPEEATproLP)
Measured
65%
6m
15m
84m
91
Expected
75%
6m
15m
48m
45
Major findings:
 mainline C=80
 pump effy 65%
Potential annual savings $5,515
($56k amortised over 10 yrs)
Justifies pipeline efficiency audit
Copyright 2017 TALLEMENCO PTY LTD
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Case Study 2: Flood 2011




Flood Pumps, Hay NSW
Emitter type Flood
Direct drive
5600 ML /yr
$20,400/yr
10c/kWh. ave
5.3m pumped head
Residual
Pressure
at centre
line of
outlet
0 kPa
Surface motor
No filter
Static Head, metres
River level
“mean”
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Component.
Pump effy
Elevation m
Residual head m
Sum of head
components
$$/ML annual
pumping cost
Case Study 2: Flood (IPEEATproLP)
Measured
43%
5.1m
0m
5.4m
3.8
Expected
75%
5.1m
0m
5.4m
2.2
Major
findings:
pump
effy 43%
Potential annual savings $7,450
($76k amortised over 10 yrs)
Justifies pumping energy audit
Copyright 2017 TALLEMENCO PTY LTD
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Case Study 3: Knocker/Drip 2015
Residual Pressure
end of R/M - kPa
260 Ha Mixed Irrigation, built 1960’s
VFD’s
No filter
Static Head,
55 metres
Surface pump
Direct
drive
Water
level




1388 ML /yr
$160,000/yr
20.5c/kWh. ave
120m pumped head
River
Murray
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Pump effy
Elevation m
Sum of head
components
$$/ML annual
pumping cost
Measured
65%
55m
80
84m
115
Expected
75%
55m
140
48m
58
C Value
Component.
Case Study 3: Knocker/drip 2015
(IPEEATproLP)
Major findings: Mainline with
C=80, pump effy 65%
Total Potential annual savings $79,000
 Justifies pumping energy audit ($25k/yr)
 Justifies pipeline efficiency audit ($54k/yr)
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Case Study 4: Centre Pivot (IPEEATproLP audit only)
260 Ha Mixed Irrigation
VFD’s
Residual Pressure
end of R/M - kPa
Filter
Static Head,
63 metres




Surface pump
Direct
drive
1425 ML /yr
$247,000/yr
18.2c/kWh. ave
108m pumped head
Water
level
River
Murray
Copyright 2017 TALLEMENCO PTY LTD
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Case Study 4: Centre Pivot
Major findings:
 Pump effy annual 33%
 Pump effy peak flow 67%
 Mainline effy 102% (over-optimized)
Potential annual savings $133k
($1.4mill amortised over 10 yrs)
Justifies pumping energy audit
Copyright 2017 TALLEMENCO PTY LTD
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Why use IPEEATpro as an auditing tool?
1)
Saving tax payers money in Govt Energy
Efficiency programs
2)
Expedites Energy Efficiency Programs
3)
Optimising needs for pump specialist
resources for site audits
What future for pump testing?
1)
Verifying IPEEATpro audits to
AS/NZ 3598.2 Type 2
2)
Specialist testing for very large
water supply and irrigation
pumps
3)
Commissioning testing
Copyright 2017 TALLEMENCO PTY LTD
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Proudly Presented by ..
Prepared by
Tallemenco Pty Ltd
ABN 92 105 345 506
PO Box 74, Greenacres, S.A., 5086Australia
[email protected] www.talle.biz
Mob 0414 492 256
Int’l Cell +61 414 492 256
"Pumping and Hydraulics' Solutions for Irrigation and Water Supply"
Copyright 2017 TALLEMENCO PTY LTD
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Who is Tallemenco? (SA based Company)
•
Rob Welke, MD, 49 yrs in water industry
•
including 25 yrs with SA Water, testing pumps
and pipelines
•
Including 24 yrs in irrigation industry
•
Including 14 yrs practising as a pumping and
hydraulic consultant (Tallemenco)
•
No Commercial ties (no affiliation with products
or companies)
•
Member of American Society of Irrigation
Consultants
•
Assoc. Diploma Mechanical Engineering
•
Certified Irrigation Agronomist
•
Certificate IV, Training and Assessment
Copyright 2017 TALLEMENCO PTY LTD
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