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Pumping Plant Fuel Pumping Plant Fuel ComparisonComparison
By Clare Prestwich
Irrigation EngineerNatural Resources Conservation Service
Natural Resources Conservation Service
Jan 2002
Natural Resources Conservation Service
Pressure ….Pressure ….
• How do I get it?How do I get it?– ElectricElectric
– DieselDiesel
– GravityGravity
• What works Best?What works Best?
• What can I Afford?What can I Afford?
Jan 2002
Natural Resources Conservation Service
System ParametersSystem Parameters
• 160 acres160 acres
• Grow - hay,potatoes, grain, and beetsGrow - hay,potatoes, grain, and beets
• System operates 1800 hours per seasonSystem operates 1800 hours per season
• applies maximum of .32”/ DAY - applies maximum of .32”/ DAY - 36”/SEASON36”/SEASON
• Irrigated by a Center PivotIrrigated by a Center Pivot
• 7 year Capital Recovery Period7 year Capital Recovery Period
• 10% Interest rate on operating funds10% Interest rate on operating funds
Jan 2002
Natural Resources Conservation Service
Pivot Layout
Operating Pressure 50psisurface water no other pumping lift required
Jan 2002
Natural Resources Conservation Service
Horse power - hour per Horse power - hour per Unit of FuelUnit of Fuel
1.2
15
10.59.5
0
2
4
6
8
10
12
14
16
BPH
ElectricDieselGasolinePropane
Fuel type
Jan 2002
Natural Resources Conservation Service
Electric Pump stationElectric Pump station
Jan 2002
Natural Resources Conservation Service
Find Total Pumping HeadFind Total Pumping Head
System Parameters
PipeFricton Factor
10.00 150 251,867.00 5
6.65 140 25.21,280.00 10
950.00 58.1
117.6
System Information Operating Pressure
Supply Pipe Diameter (in) Nozzle pressure (psi)
Supply Pipe Friction Loss (ft)
Total (ft)
Pivot length (ft)System Flowrate (gpm)
Elevation +/- (12)Minnor losses (ft)
Distance from pump to pivot (ft)Pivot pipe Diameter (in)
Presure regulators loss (psi)Pivot Friction Loss (ft)
Total head required 117.6’
Jan 2002
Natural Resources Conservation Service
Find Horsepower and Find Horsepower and energy neededenergy needed
Other Efficiency Total BHP per Operation Units of Water Horse needed Pump Motor Other Horse Power Unit of per season Fuel power (hp) Power (hp) (%) (%) (%) Requirement Fuel (hr) Needed
28 85 95 34.9 1.2 1800 52402.4
Need 35 hp pumpand 52402 kw-h of fuel
Jan 2002
Natural Resources Conservation Service
Operating CostsOperating Costs• Annual Cost of FuelAnnual Cost of Fuel• Oil- for MotorOil- for Motor
– 4000 whp-hrs/gal4000 whp-hrs/gal
• Repairs and MaintenanceRepairs and Maintenance– $1/bhp-hr/1000 hr$1/bhp-hr/1000 hr
• Annual Cost of LaborAnnual Cost of Labor– 0.02hrs/hr of operation0.02hrs/hr of operation
• Center Pivot OperationCenter Pivot Operation– hp*hrs/1.2 BPHhp*hrs/1.2 BPH
Jan 2002
Natural Resources Conservation Service
Annual Operating CostsAnnual Operating Costs
Cost
Escalation SubItem Amount Units Cost/unit % Total
Fuel 52402 kw-h $0.06 0.0 $3,144oil 1 gal $8.00 $8repair 1 job $400.00 $400Labor 50 hrs $8.00 $400Pivot Operation 15750 kw-h $0.06 $945
Total Operating cost $4,897
Yearly operating cost of $4897
Jan 2002
Natural Resources Conservation Service
Pump station Investment Pump station Investment CostsCosts
Return Interest Investment AnnualAmount Units Cost/Unit period (yrs) Rate (%) Cost Cost factor cost
1 Job $6,500.00 7 10 $6,500 0.205405 $1,3351 Job $2,000.00 $2,000 $4111 job $2,000.00 $2,000 $4111 Job $400.00 $400 $82
$0 $0$0$0$0$0$0
Cost Sub Total $10,900 Annual $2,239
ItemPump and fittings
Electrical Panel & mis.Power hook up
Electrician Labor
Annual invest cost $2239
Jan 2002
Natural Resources Conservation Service
Final ResultsFinal Results
FixedOperating
Total
$/Acre-Inch0.59$ 1.30$
$/Acre18.95$ 41.45$
60.40$ 1.89$ 3.96$ 7,136$
Annual$/Hour1.24$ 2.72$
2,238.92$ 4,897.14$
Jan 2002
Natural Resources Conservation Service
Other possible costOther possible cost
• Phase ConverterPhase Converter
• Power LinePower Line
Jan 2002
Natural Resources Conservation Service
With Phase ConverterWith Phase Converter
FixedOperating
Total
Annual$/Hour1.81$ 2.91$
3,265.95$ 5,246.49$
72.05$ 2.25$ 4.73$ 8,512$
$/Acre-Inch0.86$ 1.39$
$/Acre27.64$ 44.41$
FixedOperating
Total
Annual$/Hour2.84$ 2.72$
5,114.60$ 4,897.14$
84.74$ 2.65$ 5.56$ 10,012$
$/Acre-Inch1.35$ 1.30$
$/Acre43.29$ 41.45$
With 1/4 mile power lineWith 1/4 mile power line
Jan 2002
Natural Resources Conservation Service
Diesel Pumping StationDiesel Pumping Station
Jan 2002
Natural Resources Conservation Service
Find Horsepower and Fuel Find Horsepower and Fuel needsneeds
Other Efficiency Total BHP per Operation Units of Water Horse needed Pump Motor Other Horse Power Unit of per season Fuel power (hp) Power (hp) (%) (%) (%) Requirement Fuel (hr) Needed
28 15 85 70 72.6 15 1800 8715
With extra horsepower to run Pivot75 hp pump8715 gals of fuel
Jan 2002
Natural Resources Conservation Service
Investment costsInvestment costs
CapitalReturn Interest Investment Cost Annual
Amount Units Cost/Unit period (yrs) Rate (%) Cost factor cost1 ea $18,000.00 7 10 $18,000 0.2054 $3,6971 ea $700.00 $700 $1441 ea $500.00 $500 $103
$0 $0$0 $0
$0$0$0$0$0
Cost Sub Total $19,200 Annual $3,944
ItemPumping Plant and Generator
TankPad
Annual cost $3944
Jan 2002
Natural Resources Conservation Service
Operating CostOperating Cost
• Annual Cost of FuelAnnual Cost of Fuel• Oil engineOil engine
– 900 whp-hrs/gal900 whp-hrs/gal• Oil Gear DriveOil Gear Drive
– 4000 whp-hrs/gal4000 whp-hrs/gal• Repairs and MaintenanceRepairs and Maintenance
– $3.75/ bhp-hr/1000/hr$3.75/ bhp-hr/1000/hr• Annual Cost of LaborAnnual Cost of Labor
– 0.02hrs/hr of operation0.02hrs/hr of operation
Jan 2002
Natural Resources Conservation Service
Operating CostsOperating Costs
Cost
Escalation SubItem Amount Units Cost/unit % Total
Fuel 8715 gal $0.73 $6,362oil 86 gal $8.00 $688oil -gears 19 gal $8.00 $152repairs 135 hrs $3.75 $506labor 36 hrs $25.00 $900
Total Operating cost $8,608
Yearly Operating cost $8608
Jan 2002
Natural Resources Conservation Service
Final ResultsFinal Results
FixedOperating
Total
$/Acre-Inch1.04$ 2.28$
$/Acre33.38$ 72.86$
106.24$ 3.32$ 6.97$ 12,552$
Annual$/Hour2.19$ 4.78$
3,943.79$ 8,607.92$
Jan 2002
Natural Resources Conservation Service
All Things being equalAll Things being equalwhere is is the break even pointwhere is is the break even point
00.020.040.060.080.1
0.12
Electric Costs ($)
Die
sel
Cost
s
Diesel vs. Electric Equivalent costs
$0.90 $1.00 $1.25 $1.50
Jan 2002
Natural Resources Conservation Service
Operating Costs
0
1000
2000
3000
4000
5000
6000
1 3 5 7 9
Percent of Engery Escalation (%)
Do
llars
($)
6" Pipe
8" Pipe
10" Pipe
12" Pipe
15" Pipe
Effects of Energy EscalationEffects of Energy Escalation
Jan 2002
Natural Resources Conservation Service
Pipe SizingPipe Sizing
• Is it cheaper to buy larger pipe and Is it cheaper to buy larger pipe and less pumping head or smaller pipe less pumping head or smaller pipe and more pumping head?and more pumping head?
Jan 2002
Natural Resources Conservation Service
Economic Pipe Size Economic Pipe Size based on 950 gpmbased on 950 gpm
electric @$0.06/Kw-hr, diesel @ $.73/galelectric @$0.06/Kw-hr, diesel @ $.73/gal
8 8
10
0
2
4
6
8
10
inches
Electric Diesel 5fps
Jan 2002
Natural Resources Conservation Service
Economic Flow rateEconomic Flow ratebased on Energy Price Escalationbased on Energy Price Escalation
10” pipe Diesel @$1.3010” pipe Diesel @$1.30
843831
808
785
750760770780790800810820830840850
0% 1% 3% 5%
Diesel
Jan 2002
Natural Resources Conservation Service
How about Gravity How about Gravity Pressure?Pressure?
Jan 2002
Natural Resources Conservation Service
How far Can I afford to How far Can I afford to go?go?
Based on
•Annual cost of $7136
•7 year pay off
Jan 2002
Natural Resources Conservation Service
Instead of installing a electric pump Instead of installing a electric pump station You can install how many feet of station You can install how many feet of pipe… ?pipe… ?
Equivalent Gravity Pipe LengthTotal
Operating ElevationPipe Material Installation Length Friction Loss Pressure RequiredRequired Average
Diameter ID (in) $/ft $/diameter-inchCost factor ft ft ft ft slope
10.00 $3.50 $0.25 0.21 5204 22.50 117.59 140.09 2.69%
5204’ of pipeBut 140’ of fall is needed
Jan 2002
Natural Resources Conservation Service2000.00
3000.00
4000.00
5000.00
6000.00
7000.00
8000.00
9000.00
10000.00
5 7 10 15 20
Pay back Period (yrs)
Le
ng
th o
f P
ipe
(ft
)
10" pipe
6" pipe
8" pipe
12" pipe
15" pipe
Pipe Length vs. Capital Recovery Pipe Length vs. Capital Recovery PeriodPeriod
Jan 2002
Natural Resources Conservation Service
Head vs. Pipe Length Head vs. Pipe Length Gravity presure vs. Pumping
100.0
150.0
200.0
250.0
300.0
350.0
400.0
450.0
500.0
550.0
600.0
2000 4000 6000 8000 10000
Pipe Length (ft)
Ele
vati
on
He
ad
Ne
ed
ed
(ft
)
6" pipe
8" pipe
10" pipe
12" pipe
15" pipe
Jan 2002
Natural Resources Conservation Service
Questions?Questions?
Jan 2002
Natural Resources Conservation Service
Thank You!Thank You!And And
Happy FarmingHappy Farming