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Remote Solar & Wind Electric Stock Water Pumping: Technical Overview
Milton Geiger
Energy Extension Coordinator
Powell, WY
July 8, 2010
Overview*
Solar energy basics Growing use in the USA
Solar powered pumping – a mature technology
Environmental issues
Cost analysis of solar powered stock watering systems
Wind power Sometimes a cost effective option
Operation & maintenance issues Winter freeze protection
Conclusion Taking info to action!
*Based upon presentation by Motor Training & Testing Center, UW Department of Electrical & Computer Engineering
Demonstration – Look over one that works…
Solar Energy Overview
Photovoltaic cells – How do they work?
Source: Florida Solar Energy Center
Solar Energy Overview – Lots of cells make a panel
Source: Florida Solar Energy Center
Solar Electric Usage in the USA
Source: The Solar Energy Industries Association (SEIA), 2009 U.S. Solar Industry Year in Review,
Wyoming's Solar resource
Park County Solar Radiation
kW
h/
m2
/d
ay
5.24
Source: NREL PVWatts
The Other Solar – Thermal Heating
Solar Powered Livestock Water Pumping – A Mature Technology
Photo Credit: Steve Fletcher – Weston County, WY
UW/Conservation District Demonstration Project
Demonstration units installed 2005-2006
Led by Motor Training & Testing Center, UW Department of Electrical & Computer Engineering
Dr. Sadrul Ula and Steve Fletcher
Received funds from both the Office of the Governor and NRCS
Over 75 systems installed
At least two in each county
Creation of demonstration trailer
Water pumping – Old technology
Diaphragm Pumps and DC Brush Motors…
Water Pumping – Helical Rotor Pumps
Evolution of Water Pumping in Wyoming
Surviving the Wyoming Environment – Issues
Hail!
Design to withstand hail up to baseball size
Wind!
Impact design of systems
Sturdy frame for the solar panels, adequate gap between panels to allow for wind to pass
Skeptical of trackers
The Death of a windmill…
Solar Trackers in Wyoming
Designing a Good Solar System
Water Information – Well & pipeline
Information about the well
Static water level
Draw down water level
What flow rate
Well casing size
Depth of well
Pipeline Information
Pipeline size
Total length of line and elevation change
Water Information – Livestock use
Month Avg. Max. Temp.
Cows Bulls Growing Cattle
Nursing Calves
Bred Dry Cows & Heifers
400 lb 600 lb 800 lb
°F GAL GAL GAL GAL GAL GAL January 36 11 6 7 3.5 5 6
February 40 11.5 6 8 4 5.5 6.5 March 50 12.5 6.5 8.6 4.5 6 7 April 64 15.5 8 10.5 5.5 7 8.5 May 73 17 9 12 6 8 9.5 June 78 17.5 10 13 6.5 8.5 10 July 90 16.5 14.5 19 9.5 13 15
August 88 16.5 14 18 9 12 14
September 78 17.5 10 13 6.5 8.5 10 October 68 16.5 8.5 11.5 5.5 7.5 9
November 52 13 6.5 9 4.5 6 7 December 38 11 6 7.5 4 5 6
Source: Paul Guyer, University of Nebraska G77-372, 1977
Design – Solar pump suppliers
Design – Where are my batteries?
Battery-based systems are generally not cost effective
Batteries
Add resistance, reducing output
Expensive
Require regular maintenance
Need to store energy?
Get a bigger water tank!
Design – Solar Pumping Systems
Approximate Equipment Cost
Small System - $2,500 100’ Lift – 1,200 GPD, 3 GPM 50’ Lift – 2,200 GPD, 5 GPM
Medium System - $4,000-$5,000 400’ Lift – 1,000 GPD, 2.6 GPM 200’ Lift – 2,500 GPD, 5 GPM 50’ Lift – 5,000 GPD, 10 GPM
Large System - $7,500-$8,500 600’ Lift – 1,000 GPD, 1.8 GPM 300’ Lift – 2,600 GPD, 5 GPM 100’ Lift – 8,000 GPD, 14 GPM
Gallons per minute figures are peak flow
When is it Cost Effective? –Example
AC Pump - $700 est. 10 GPM
1 HP Single Phase Franklin 4” Pump Motor
Motor Starter
Cost of Gasoline - $2.75 / gallon
Line Extension Cost - $20,000 / mile
Cost of AC Power - $0.11 / kWh
Line Connection Charge - $26.00 / month
Generator – Honda EB5000 $2,484 MSRP
Specs from hondapowerequipment.com
When is it Cost Effective? –Example
Lorentz PS1200, HR-14 Pump - $1800 est.
1000 Watt Solar Array $5000 est.
System will pump, with 165’ lift:
5500 gpd summer
4800 gpd fall/spring
4000 gpd winter
10 gpm maximum pump rate
In order to compare with this solar system, the cost for the AC systems are calculated using these production quantities.
When is it Cost Effective? –Example
10 Mile Round Trip to Check on Well
7 days a week for generator (fueling)
1 day a week for utility line powered
4 days a week for solar system
Assume your truck gets 15 mpg
At 165’ lift, the AC pump will have 60 psi of pressure at outlet in order to limit the flow rate to 10 gpm.
When is it Cost Effective? –Example
5-Y
ear D
isco
un
ted
Co
st
Distance from Electrical Service
AC
Solar
Solar w/ Incentives
Generator
Wind Power
More economical than PV
PV – Approximately $4.50/watt
Wind – Whisper 200 $2.25/watt
More maintenance and problems with Wyoming’s “strong” wind resource
Allows for pumping during low light daytime conditions and at night
Demonstration Unit
Four 170W Sharp solar panels
~$2400
One 400W Southwest Wind Power Air X wind turbine
~$1000
Grundfos 3 SQF-2 120 - 390 3 47 1" NPT helical rotor pump
~$1800
Grundfos CU200 SQFlex pump controller
~$290
Trace Engineering Model 2524 inverter*
~$1800
Batteries – Deep Cycle Marine/RV
~$400
Demonstration Unit
Total cost without inverter
$4,636
Total cost with inverter and batteries
$6,422.00
If pump properly sized (e.g 25SQF-6) could pump
~7000+ gpd in January
~8500+ gpd in July
Variability from wind turbine…
Maintenance/Operation Issues
Specific technical glitches can be discussed at demo trailer
Freezing concerns
Solar/wind powered heaters are not (generally) a good idea
Use the same strategies as you would with any stock water well
Remember:
Smooth operation is preceded by careful and correct design!
Resources
List on resources and contacts provided in the folder
National Sustainable Agricultural Information Service
http://www.attra.org/attra-pub/farm_energy/
eXtension
www.extension.org
“Ask an Expert”
Grundfos WebCAPS
http://net.grundfos.com/Appl/WebCAPS/
Google “Grundfos webCAPS”
Conclusion – Now what?
More questions?
Call UW CES
307.766.3002
Manufacturing Works
800.343.1423
Talk to a dealer
Make sure you know enough to “be dangerous”
Use those incentives!
30% tax credit
Accelerated depreciation
NRCS EQUIP
Rural Development Section 9007
Contact Milton Geiger
(307) 766-3002
Contact Information
Solar Pumping - 1991
Solar Pumping - 2000
Solar Pumping - 2005
Out With the Old and In With the New
Bobby Brubaker – Washakie County
Arny Larson – Lincoln County
Alan Todd – Weston County
Design Example 2
New well with 2 mile pipeline to storage tank – then gravity flow to open tanks
Has a 5” PVC casing
100’ deep, static water level at 50’
At 5 GPM well draws down to 60’
150 Pairs will use this water at one time
Pipeline runs 2 miles with 150’ increase in elevation and is 1.5” HDPE
Design Example 2
Total water needed:
150 X 20 = 3000 GPD summer
150 X 12 = 1800 GPD winter
Total head, at 5 GPM, is 60’ + 150’ + Friction loss in pipe
Friction loss = .18’ of head per 100’
5280 X 2 / 100 X .18 = 19.008’
Total Head = 229’
Design Example 2 Time to go to the Pump Charts:
First up, Lorentz PS1200
Design Example 2 Time to go to the Pump Charts:
Next up, Grundfos SQ Flex
Design Example 2 What will the 11 SQF 2 produce in the winter sun?
8.5 GPM X
4.5 Hr X 60
min/HR
=
2295 GPD
Design Example 2
In this case the SQF Produces more water in the summer, however at a higher flowrate which could cause problems with draw down and increased friction losses in the pipeline resulting in a higher head.
The PS1200 HR-14 will produce enough water in both winter and summer while not overloading the well.
Again, both systems use the same size of solar array.
Design Example 2
Lorentz HR-14 Pump
PS1200 Controller
1000 Watt Array – 72-96 Volts DC
6 X 165-170 Watt Panels
8 X 125 Watt Panels
10 X 100 Watt Panels
Rack for Mounting Panels
3 Wire with ground Submersible Pump Cable, Pipe, Safety Rope and 2 wire sensor cable
Optional
AC Power Pack Generator Converter
Design – Now you have all you need!
Grundfos SQ Flex Chart
Design – Now you have all you need!
Lorentz PS600/PS1200 Chart
Design – Example
Old windmill, produces ~10 GPM
Has a 4” steel casing
100’ deep, static water level at 40’
200 Pairs water at this location
Well empties to open tank at well head
Design – Example
Total water needed:
200 X 20 = 4000 GPD summer
200 X 12 = 2400 GPD winter
Drawdown is unknown, so assume the pump will be at 95’. Therefore maximum head will be ~92’ due to the low water sensor protection.
Pump is limited to 10 GPM flow rate
Design – Example
Review the pump charts: Lorentz
Design – Example
Review:
Next up, Grundfos SQ Flex
Design- Example
10.15 GPM
X 4.5 Hr X
60 min/HR
=
2740 GPD
Design Example
Since both systems are similar in size and production which one to pick?
Well casing is 4”, the SQ Flex is 3” diameter and the HR-14 is 3.875” in diameter.
SQ Flex is the only system that will fit in the casing, regardless of other considerations
Your preference of manufacturer!
Design Example
Grundfos 11 SQF 2 Pump
IO 101 Switch Box
500 Watt array – 30-300 Volts DC
3 X 165-170 Watt Panels
4 X 125 Watt Panels
5 X 100 Watt Panels
Rack for Mounting Panels
Includes 2 wire with ground submersible pump cable, pipe, safety rope
Optional
CU 200 Control Unit
Design – Not a fan of pump charts?
Call your dealer for pump/motor design
Grundfos WebCAP
http://net.grundfos.com/Appl/WebCAPS/
Water Information – Design Specs*
Amount of water required by livestock – Cow-calf pair
Summer 15-20 gallons per day (GPD)
Winter 10-12 GPD
Yearling Summer 12-15 GPD
Winter 10-12 GPD
Sheep Summer 2-4 GPD
Winter 1-2 GPD
Horse about same as cow/calf pair
* As estimated by UW EMTTC
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