FINAL PROJECT REPORT

Diesel Pumping Efficiency Program

Submi e! o Roy For! "#S# EPA$ Region % &' (a) *orne S ree $ AIR+, San Francisco$ CA# %-./'

0y Jo*n 1e!!ing on$ Pe er Canessa California S a e "ni2ersi y Fresno Cen er for Irriga ion Tec*nology ''%#3&,#3/44

Oc ober 5.$ 3//4

FINAL PROJECT REPORT (OCTOBER 31, 2006) CAA Special Purp !e Ac"i#i"ie! $ %ie!el Pu&pi'( E))icie'c* Pr (ra&
EPA +ra'" Nu&,er- 6A 7 %4%-/-/. + / I'#e!"i(a" r!- Jo*n 1e!!ing on$ Pe er Canessa$ California S a e "ni2ersi y Fresno 8CS"F9 ''%#3&,#3/44 EPA Pr .ec" O))icer- Roy For! T "al Pr .ec" Peri /- Oc ober .$ 3//' + Oc ober 5.$ 3//4 T "al Pr .ec" Bu/(e"- :'/$/// Re!earc0 Ca"e( r*- 44#/5- 7 Sur2eys+S u!ies+In2es iga ions+Demons ra ions an! Special Purpose Ac i2i ies rela ing o *e Clean Air Ac Pr (ra& C 'cep"T*e propose! pilo +le2el Diesel Pumping Efficiency Program 8DPEP9 a!!resses s a ionary an! por able agricul ural )a er pumps po)ere! by !iesel engines# DPEP 2ie)s *e pumping plan as a sys em of *ree mec*anical componen s+ .9 po)er source$ 39 po)er ransmission$ an! 59 *e pump i self$ an! one *uman componen $ *e managemen of *e e;uipmen # To *e e< en *a *ere are inefficiencies in any of *ese componen s$ or =us as impor an ly$ *e managemen of *e sys em$ opera ional ime is increase! along )i * emissions# T*e purpose of *is pilo +le2el program is o impro2e *e efficiency of *e pump i self$ *ereby impro2ing *e en ire pumping sys em$ resul ing in re!uce! air emissions by re!ucing fuel consump ion# T*e pilo DPEP )ill pro2i!e subsi!i>e! pump efficiency es s an! incen i2e reba es for re rofi an! repair of inefficien pumps 8no engines or ransmission sys ems9# A final repor )ill a!!ress *e basic *esis using *e resul s of all pump es s bu especially *e before an! af er es s of *e pump repair pro=ec s# I )ill es ima e an! commen on curren fiel! performance of !iesel+po)ere! pumping plan s an! recommen! )*e *er or no *e pro=ec s*oul! be e<pan!e!# T*e si e for *e DPEP is *e San Joa;uin ?alley of California$ curren ly in *e process of ac*ie2ing @a ainmen A s a us for air ;uali y s an!ar!s rela e! o bo * par icula es an! o>one# Pr (ra& 1 r2 Pla' C &p 'e'"! a'/ E3pe'/i"ure! 8a! !u,&i""e/ i' ri(i'al (ra'" pr p !al).# Program Banagemen 7 )el2e 8.39 mon * ime frame$ #/. )orC years + :.$/// 7 !esign an! managemen of *e pro=ec $ liaison )i * EPA$ ;uar erly repor ing$ liaison )i * CS" Fresno# 3# Program Ou reac* 7 nine 8%9 mon * ime frame$ #//,5 )orC years + :'// 7 i!en ify par icipan s for pump efficiency es s an! repair pro=ec s by a en!ing 2arious ra!e group mee ings an! alCing )i * pump repair companies# 5# -/ Pumping plan efficiency es subsi!ies a :3'/ eac* 7 nine 8%9 mon * ime frame$ :./$/// fe!eral# O2erall pumping plan efficiency is !efine! asD OPE E .// < 1(P F (Pin 1*ereD OPE E o2erall pumping plan efficiency as a percen 1(P E )a er *orsepo)er ou pu from *e pumping plan (Pin E po)er inpu o *e pumping plan as fuel .

AlsoD 1(P E G < TD( F 5%4/ 1*ereD 1(P E )a er *orsepo)er ou pu from *e pumping plan G E flo) in gallons per minu e from *e pump TD( E o al !ynamic *ea! in fee !e2elope! by *e pumping plan AlsoD (Pin E gallons of !iesel per *our < '' *ermal (P+(ours per gallon of !iesel During a pump efficiency es $ *e es er )ill measure fuel consump ion$ *e !ifferen componen s of o al !ynamic *ea! 8pumping )a er le2el$ !isc*arge pressure9$ an! )a er flo) in *e pumping sys em# Pump !emograp*ics suc* as ype of use$ annual *ours of opera ion$ pump ype$ manufac urer of *e pump$ engine$ gear *ea!$ ype of farm$ o al acres farme!$ an! a2erage fuel cos s 8as able9 are also ga *ere! !uring *e es # Pump efficiency es s pro2i!e a benc*marC for pumping plan efficiency# In con=unc ion )i * annual opera ing ime an! a2erage fuel cos s *ey can be use! o !e ermine an es ima e of fuel cos sa2ings resul ing from a pump re rofi Frepair# Pre an! pos +re rofi es s are performe! o !e ermine ac ual resul s# T*e pump efficiency repor s pro2i!e! o clien s )ill inclu!e e!uca ional ma erial regar!ing correc managemen of pumping plan s# -# Incen i2e reba es for 4 pump re rofi Frepair pro=ec s 7 en 8./9 mon * ime frame$ incen i2e reba e of up o :5$'// per re rofi pro=ec bu no o e<cee! 5'H of *e pro=ec cos # + :3.$/// fe!eral an! :5%$/// clien s*are++ pump re rofi s are es ima e! o cos appro<ima ely :./$/// o al eac*# If an incen i2e reba e is less *an :5$'//$ i may be possible *a more *an 4 pro=ec s )ill be fun!e! bu no o e<cee! :3.$/// in o al incen i2es# Pump efficiency es s )ill be aCen bo * before an! af er a pro=ec o =u!ge *e impro2emen in pumping plan efficiency# No engine mo!ifica ions or une+ ups$ nor any )ell re*abili a ion ac i2i y )ill be eligible# T*e purpose of *is program is solely o =u!ge *e re!uc ion in emissions a2ailable *roug* pump re rofi ing# 8No e 7 pump re rofi pro=ec s )ill be comple e! by *e repair company of clien Is c*oice# T*e incen i2e reba e is no appro2e! unless an in2oice marCe! PAID is submi e!# T*is is proof *a *e pro=ec )as performe! o *e clien Is sa isfac ion#9 Reba e recipien s )ill recei2e e!uca ional ma erial regar!ing correc managemen of pumping plan s# '# Re2ie)FAppro2alFDa abasing of pump efficiency es s an! re rofi Frepair pro=ec s 7 ele2en 8..9 mon * ime frame$ #/.4& )orC years + :.$/// 7 re2ie) submi e! pump efficiency es s an! pump re rofi pro=ec s for eligibili y for subsi!ies an! re rofi reba es$ respec i2ely$ racC es s an! re rofi s$ liaison )i * con rac e! pump efficiency es ers$ an! en er !a a in o *e DPEP !a abase# Repor e! pump es s are sub=ec e! o a re2ie) of *e !a a se for reasonableness 8i#e# i )oul! be impossible for a !iesel+po)ere! pumping plan o be measure! )i * an OPE abo2e -/H9 an! comple eness 8i#e# curren ly *e APEP !oes no subsi!i>e a pump es unless *e OPE an! *e pumping cos analysis can be compu e!9# Eligibili y cri eria for a re rofi )oul! inclu!e an opera ing pump *a is use! for agricul ural pro!uc ion# T*e applica ion for a re rofi )ill inclu!e a copy of *e pre+pro=ec pump efficiency es $ a signe! agreemen be )een *e pump o)ner an! DPEP$ an e<plana ion as o *e na ure of *e 3

re rofi pro=ec $ an! pump !emograp*ics suc* as ype of use$ annual *ours of opera ion$ pump ype$ manufac urer of *e pump$ engine$ gear*ea!$ ype of farm$ o al acres farme!$ an! a2erage fuel cos s# T*e comple e! applica ion rea!y for issuance of *e reba e )ill inclu!e a copy of *e repair company in2oice an! *e pos +pro=ec pump efficiency es # 4# Repor !escribing feasibili y of e<pan!ing *is ype of program 7 si< 849 mon * ime frame$ #/4 )orC years + :-$/// 7 summari>e an! commen on apparen fiel! efficiencies in!ica e! by *e pump es s$ summari>e an! commen on *e si< pump re rofi pro=ec s an! *eir resul s$ commen on recep ion of e!uca ional ma erial$ maCe recommen!a ions for e<pan!ing *e pilo pro=ec # Pr (ra& Su&&ar* (Oc" ,er 1, 2004, " Oc" ,er 31, 2006) 1. Program Management Program ac i2i ies *a2e been on+going since Augus of 3//'# No e *a an earlier s ar )as ma!e possible by fun!ing from *e non+profi ?alley CAN 8@Clean Air No)A9 group# T*e goals an! financials for *ese programs )ere manage! in!epen!en of eac* o *er$ al *oug* a single program )as offere! o *e public# Banagemen !u ies inclu!e! program ou reac*$ re2ie) an! !a abasing of pump es s$ repair reba e processing$ !iscussions )i * pump o)ners regar!ing *e benefi s of a repair$ an! o *er ;ues ions regar!ing reba e pro=ec s# Applica ion forms$ pump es repor ing forma s an! formulas$ researc* of engine specifica ions$ an! o *er programma ic ma erials *a! o be !e2elope!# T*e program *as ac*ie2e! all of i s s a e! goals$ )i * a!!i ional pump es ing inclu!e! as )ell# 2. Pump Testing A o al of -, pump es s )ere performe! for *e program$ )i * -& of *ose es s pai! by *e Program an! . of *e es s pai! by *e cus omer# T*e Program goal )as o es -/ pumps# A!!i ional pumps )ere es e! o use up *e unspen re rofi money 8bu!ge e! a :3.$///+++ :.%$,,& )as spen on pro=ec s9 an! ra2el cos s# No e *a pump es ing lea!s o a!!i ional pump re rofi s an! emission sa2ings# T*e es s )ere performe! a *e re;ues of *e e;uipmen o)ner$ or as a pos re rofi es 84 o al9 o 2erify resul s from *e repair# An effor )as ma!e o limi *e number of es s per e;uipmen o)ner o *ose uni s *a )ere ;ues ionable in pump performance an! o screen for pumps *a *a! goo! or 2ery goo! engines 8recen Boyer Program engine recipien s9# Since *is is a @pilo A pro=ec $ our goal is o i!en ify ypical !iesel pump efficiency for *ose sys ems *a are in regular usage an! liCely o remain as a !iesel !ri2en pumping plan # 1e !eeme! *a Boyer pro=ec s )ere *e mos liCely can!i!a es for represen ing any fu ure programma ic effor s# A!!i ionally$ )e !esire! o elimina e as muc* as possible any issues *a )ere rela e! o )orn ou or faul y engines# A fur *er screening )as performe! o fin! e;uipmen *a *a! *ig* annual *ours of opera ion so *a *e economics from sa2ings )oul! influence *e o)ner o in2es in a repair# T*ese !iscussions )ere ma!e informally )i * *e farmer prior o *e ac ual es ing# In general$ our goals )ere aligne! )i * *e goals of *e e;uipmen o)ners$ )*o soug* o i!en ify *e e;uipmen )i * *e mos rapi! pay bacC on *eir upgra!e !ollar# Screening accor!ing o recen year engines also ma!e sense o *e o)ner$ as i is *is e;uipmen *a *e o)ner )as mos !epen!en upon for *eir irriga ion re;uiremen s# T*e !iesel pump es proce!ures$ e;uipmen $ an! resul s are a ac*e! in Appen!ices . an! 3# 5

3. Pump Retrofit Of *e -, pump es s performe!$ si< of *ese es s *a2e resul e! in comple e! re rofi s# An a!!i ional , pump re rofi s )ere ei *er pos pone! un il a la er !a e$ or *a! complica ions !uring *e re rofi process *a pre2en e! *e full re rofi from being reali>e!# Some of *ese pumps )ere enrolle! in o *e u ili iesI !iesel o elec ric pump con2ersion program 8@AJ+ICEA program9# T*is )oul! no nega e *e nee! of a pump re rofi $ *o)e2er i )oul! in errup *e abili y o run *e pump un il *e ne) elec ric mo or an! con rols are func ional# T*ese a!!i ional resul s *a )ill be ac*ie2e! by *e gran are !irec resul s$ bu are no repor able# Pump es resul s can influence !ecision maCing for se2eral years beyon! *e es !a e# A ypical pump re rofi cos s be )een :./$/// o :5/$/// !epen!ing on fac ors rela e! o *e si>e of *e pump$ se ing !ep *$ an! con!i ion )*en remo2e!# T*e si< pumps re rofi e! cos *e o)ners :&$./&$ :3'$&//$ :.%$3.,$ :'%$-'3$ :.&$,3-$ an! :3/$.&4 respec i2ely$ )i * an a2erage of :3-$%.5# One of *e re rofi s also inclu!e! )orC o *e )a er )ell# 1a er )ells are ypically inspec e! an! repaire! a *e ime of pump remo2al on an @as nee!e!A basis# Reba es pai! ou for *e pump re rofi s )ere :.%$,,&#,4# Fi2e of *e si< reba es ;ualifie! for *e ma<imum amoun of :5$'//# T*e pump re rofi e! a *e cos of :&$./& ;ualifie! for a reba e of 5'H of pro=ec cos $ or :3$-,&#'4# One of *e fi2e :5$'// reba es )as cos s*are! )i * *e ?alley CAN gran $ re!ucing *e EPA cos o :5$-//#5/# T*e follo)ing bulle s *ig*lig* Cey resul s of *e ProgramD A2erage O2erall Pumping Efficiency impro2e! from .-#5H o 3-#-H A2erage life ime fuel sa2ings is 35$'5' gallons per re rofi $ an appro<ima e :-&$/// pro=ec e! fuel sa2ings a :3#// per gallon of !iesel Firs year a2erage fuel cos s sa2ings o *e farmerD :&$&,& A2erage life ime NO< sa2ings is -#3 ons A2erage life ime PB./ sa2ings is /#., ons Commensura e ROJ re!uc ions )ere also ac*ie2e!$ bu *is )as no a racCe! pollu an in *is s u!y Cos per on of NO< sa2e! is un!er :&%/ per on 8ne 9$ :.$%,- per on 8gross9# A2erage )a er flo) ra e increase! from ',% o ../3 gpm )i * *e re rofi e! pump Annual *ours of opera ion re!uce! from .$,,5 o .$/'& o pump *e same )a er amoun

A pump re rofi *a pays for i self in fuel sa2ings in less *an 3 years is a 2ery liCely can!i!a e o be re rofi e!# 1i * an a2erage re rofi cos of :3-$%.5$ an! an a2erage firs year fuel sa2ings of :&$&,&$ *e pump re rofi s pai! for *emsel2es on *e a2erage in 5#3 years# No e *a a!!i ional sa2ings o *e o)ner are ac*ie2e! 2ia a re!uc ion in main enance cos s an! a longer in er2al be )een engine rebuil!s# De aile! !escrip ions of *e si< pump re rofi s are inclu!e! in Appen!i< 5 8a ac*men in E<cel sprea!s*ee 9# A ypical pump repair in2oice is inclu!e! in Appen!i< -# 4. Comments on Expansion I is clear from *e pro=ec s resul s$ an! *e !eman! for *ese ser2ices from *e agricul ural communi y$ *a a !iesel pump es ing an! re rofi program fills a clear nee!# I s*oul! be no e! *a e;ui2alen programs *a2e been on+going )i * elec ric an! na ural gas !ri2en pumps for se2eral !eca!es# T*e cri ical -

;ues ion regar!ing *e program is no one of nee!$ scope$ or si>e$ bu ra *er one of fun!ing# Since off+roa! !iesel agricul ural e;uipmen *as largely been unregula e! un il recen years$ *ere *as no ye been a a< or fee associa e! )i * *e use an! impac of *is e;uipmen on *e en2ironmen # T*ese ypes of user genera e! fees *a2e ra!i ionally been *e bes fun!ing sources for energy efficiency programs# T*e program offere! economical an! easily a ainable emission re!uc ions$ *roug* a 2olun ary measure *a impac s *e agricul ural in!us ry in an economically beneficial )ay# Ji2en *e @)in+)inA na ure of *e program$ c*anneling a!!i ional resources in o es ing an! re rofi s maCes sense# T*e measure also complemen s *e curren Boyer engine s)ap+ou program o ob ain *e *ig*es po en ial of emission re!uc ions# T*ere are se2eral program resul s *a in!ica e a clear nee! for es ing an! re rofi sD .9 T*e pre+repair o2erall efficiencies are more !e eriora e! *an e;ui2alen elec ric plan sK 39 T*e !ollar sa2ings in fuel cos s maCe paybacC more accelera e! *an e;ui2alen elec rics plan sK 59 T*e program pump es er )as *ire! o !o many more non+program pump es s on o *er !iesel irriga ion plan s o)ne! by *e farmer$ a full cos o *e pump o)nerK -9 T*e pump es o pump re rofi ra io is significan ly lo)er *an )i * elec rics# A ypical$ non+ arge e!$ mass marCe e!$ elec ric pump es ing an! re rofi program offere! by CS"Fresno resul e! in a es o re rofi ra io of abou .3 o .# 1i * *e !iesels$ -, pump es s resul e! in 4 re rofi s$ an! in!ica ions from *e o)ners *a an a!!i ional , re rofi s )oul! *appen 8probably resul ing in.re rofi s ou of -, es s9# T*e ra io is abou ,D.$ )i * per*aps a -D. ra io being ac*ie2able !uring *e ini ial p*ase of a ne) program# '9 1i * more *an '$///L !iesel irriga ion pumps opera ing in *e San Joa;uin ?alley$ a conser2a i2e nee! presen s i self for a es ing program of a leas ,// es s per year$ resul ing in .// pump re rofi s per year# Assuming a life cycle of abou 3/$/// *ours per pump$ *e replacemen cycle is abou e2ery ./+.3 years 8abou -//+'// pumps per year9 a an a2erage annual opera ion of .$%// *ours# T*e goal of *is program )oul! be o s*or en *e replacemen cycle o abou e2ery & or , years 843' pumps per year9# 49 An e!uca ional$ marCe ing$ ou reac*$ an! ec*nical assis ance componen is impor an o ac*ie2ing resul s# T*e es ing an! re rofi process re;uires a ec*nical assis ance person 8a ;ualifie! in!i2i!ual *a is able o !iscuss ec*nical issues rela e! o es ing an! re rofi s9 o be a2ailable$ as *ere are a number of ;ues ions *a are no a!!resse! by a s an!ar! pump es # For e<ample$ mul iple pumping con!i ions 8eg# open flo) 2s pressure irriga ion$ *o) acreage an! pumping re;uiremen c*anges can affec economics9 an! economic an! ec*nical ;ues ions regar!ing !ifferen fuel sources 8!iesel 2s elec ric 2s na ural gas$ off peaC pumping$ e c#9 T*e e!uca ional program as fun!e! *ere consis e! of a mailing of *e ProgramIs Pump Seminar Book. One resul of *e mailing )as *a one of *e 4 re rofi recipien s re;ues e! pump es s for all of *is elec ric irriga ion pumps 8)*ic* )ere no pre2iously es e! as par of *e o *er CS"Fresno pump es ing programs in opera ion since 3//.9# &9 T*e program )as able o maCe referrals o *e PJME an! SCE Ag+ICE an! SJ? Air Pollu ion Con rol Dis ric programs for assis ance in elec rifying cer ain !iesel plan s# T*e Ag+ICE an! SJ?APCD programs offer @>eroA emission oppor uni ies for !iesel irriga ion pumps *a are goo! can!i!a es for elec rifica ion# T*is collabora ion *elps agencies )orC in *armony o ac*ie2e cleaner air# ,9 CIT secure! a!!i ional fun!ing from *e ?alley CAN group for a secon! p*ase of DPEP# T*e goal )as o !e2elop *e cri ical pump es er infras ruc ure nee!e! in California if a large+scale DPEP )as o be implemen e!# T*e fac *a o *er groups also recogni>e *is nee! an! *a2e gran e! s ar + up fun!ing is significan # T*e secon! p*ase of DPEPinclu!es *e follo)ing componen sD '

.# 3# 5#

Es ablis*ing s an!ar!i>e! me *o!s for measuring pump es !a a in *e fiel!K De2eloping a resource manual for proce!uresK De2eloping sof )are for s oring pump es !a a an! preparing s an!ar!i>e! repor s so as o crea e a consis en @pro!uc A a2ailable o pump o)ners# -# On+si e 2isi s )i * pump es professionals in *e fiel! o presen *e !e2elope! ma erials 8 abou ./+.' companies9K In conclusion$ *e program offere! a arge e! focus on impro2ing !iesel pumping efficiency# T*e program pro2i!e! cleaner air a a compe i i2e cos an! fille! a clear nee! in *e agricul ural communi y# E<pansion o full programma ic opera ions presen s a compelling oppor uni y# (T0e re!" ) "0i! pa(e i'"e'"i 'all* le)" ,la'2)

Bu/(e" Su&&ar* (Oc" ,er 1, 2004 " Ju'e 30, 2006) BUDGET DETAIL
Actual Expenses Oct. 1, 2005, to October 31, 200 A. !ersonnel "a#es $ubtotal !ersonnel% B. *r+n#e Bene,+ts $ubtotal *r+n#e Bene,+ts% -. Tra.el Vehicle trips $ubtotal Tra.el% D. E0u+p1ent None $ubtotal E0u+p1ent% E. $uppl+es Item Office Supplies *. -ontractual Item Pump Test $ubtotal -ontracts% G. -onstruct+on N/A 2. Ot3er Item Pump Re ates $ubtotal Ot3er% $ubtotal -onstruct+on Amount $ubtotal $uppl+es% &''3.( &/00.00 &0.00 &0.00 &1,) ).51 &5 0.1( &5 0.1( &2,10).00 Project Final Amount &',003.() Full Budget Amount & ,'10.00

&/().00

&10,03 . 1 &10,03 . 1 &0.00

&10,000.00 &0.00

&21,3)'.) &21,3)'.)

&21,000.00 &21,000.00

I. Total D+rect -osts 4. In5+rect -osts At !"# of T$% 6. Total -osts

&(1, 30.0

&(1,

.00

&),32 .01 &(/,/5 .0'

&),33(.00 &50,000.00

oOo

&

Appen!i< .D Diesel Pump Tes Proce!ures an! E;uipmen Diesel Pumping Efficiency Program Sub=ec D 5INI565 FIEL% RE76IRE5ENTS FOR %IESEL P65P EFFICIENC8 TESTIN+ Sa)e"* /e#ice!- T0e pu&p "e!"er !0all 0a#e ' 0a'/ "0e ) ll 9i'( i"e&!5S%S S0ee"- %ie!el N i!e Pr "ec"i '- Ear plu(! E*e Pr "ec"i '- I&pac" re!i!"a'" e*e !0iel/ :a'/ pr "ec"i '- Appr pria"e (l #e! ) r c '"ac" 9i"0 /ie!el )uel Fuel !pill clea'up &a"erial!- Ra(! Fire e3"i'(ui!0er, /ie!el )uel ra"e/ T*e follo)ing is e<cerp e! from @Pump Efficiency Tes Reba e Informa ion PacCe 7 1a er AgenciesA as seen on 999;i"rc; r(# I is o be consi!ere! *e minimum gui!elines for performance of a ?ALID TEST# A!!i ional commen s$ in BOL%$ are aCen from *e California Associa ion of PumpTes Professionals @S an!ar! Prac icesA an! @Be *o!s an! E;uipmen A# Inser ions by CIT are ma!e in ITA ICS# @Binimum re;uiremen s inclu!e$ bu are no limi e! o$ *e follo)ingD .# Flo) ra e measuremen a# If a ec*ni;ue using 2eloci y *ea! is employe! 8e#g#$ Collins ube$ Co< ube9 for a pipe flo) ra e$ *e a2g# 2eloci y in *e es sec ion mus be grea er *an . fps# b# T*e es mus be con!uc e! using a ypical flo) ra e an! pressure# c# T*e flo) me ers an! formulas use! mus pro2i!e a LF+ -H accuracy for *e flo) ra eF2eloci y ranges *a are es e! un!er goo! es ing con!i ions# !# Reasonably accura e flo) measuremen re;uires a pipe sec ion )i *ou e<cessi2e urbulence# Table . pro2i!es minimum re;uiremen s for flo) ra e es loca ions o ;ualify for reba es of *e pump efficiency es # e# Pipe i''er /ia&e"er &ea!ure&e'"- A /irec" i''er /ia&e"er &ea!ure&e'" ) "0e pipe &u!" ,e per) r&e/ 9i"0 "0e pr per " l i) a'* )l 9 &ea!ure&e'" /e#ice calcula"e! "0e )l 9 u!i'( pipe area# f# Table . erminology can be !efine! asD .9 @Binimum !is ance re;uire! for any measuremen A in!ica es *a flo) measuremen s mus be aCen fur *er !o)ns ream 8or ups ream$ if in!ica e!9 *an *is from *e !esigna e! 2al2e or fi ing# T*e pipe sec ion *roug*ou *is !is ance mus be of a cons an !iame er$ an! be free from any in+line fi ings# Dis ances are e<presse! as @!iame ers of pipeA# For e<ample$ a !is ance of @5 !iame ersA on a .3A !iame er pipe in!ica es a !is ance of 5 < .3A E 54A# Pump es s *a rely on a flo) ra e measuremen aCen )i *in *is !is ance from *e 2al2eFfi ing !o no ;ualify for a reba e# ,

39

@Binimum !is ance re;uire! for a single ransec A in!ica es *e !is ance of clear$ unobs ruc e! pipeline !o)ns ream 8or ups ream$ if so !esigna e!9 of a 2al2eFfi ing *a mus be a2ailable in or!er o ;ualify for a single ransec es $ or for an ul rasonic es 8suc* as Paname erics$ Con rolo ron$ or o *er clamp+on uni s9# A !ouble ransec 8perpen!icular lines of 2eloci y measuremen s9 es mus be use! if *e flo) measuremen loca ion is be )een 8.9 an! 839# In general$ *e !ouble ransec s*oul! be con!uc e! using 3 segmen s of 2eloci y measuremen s aCen in planes of -' !egrees from *e op of *e pipe# (o)e2er$ *e pump es er s*oul! use !iscre ion as o *e bes configura ion# "l rasonic measuremen !e2ices 8e#g#$ Paname erics $ Con rolo ron$ or o *er clamp+on uni s9 mus follo) *e same gui!elines as *e 2eloci y measuremen !e2ices# T*a is$ *ey re;uire a minimum !is ance for any accep able rea!ing$ an! )ill re;uire a !ouble ransec rea!ing in *e same con!i ions !escribe! for CollinsF(all ubes#

59

-9

Table .# Binimum !is ance an! 2eloci y measuremen specifica ions for flo) measuremen #
Fi""i'( I% ) r Pu&p E))icie'c* Rep r" A <al#e r Fi""i'( 5i'i&u& /i!"a'ce re=uire/ ) r a'* &ea!ure&e'" 1i *in *e plane 5i'i&u& /i!"a'ce re=uire/ ) r a !i'(le "ra'!ec" . !iame er ups ream of *e ou er limi of *e plane Orie'"a"i ' ) a !i'(le "ra'!ec"

"ps ream of an elbo)

Do)ns ream of an elbo)

/#' !iame ers !o)ns ream of *e ou er limi of *e plane

3 !iame ers !o)ns ream of *e ou er limi of *e plane

D E

S)ing c*ecC 2al2e 8 *e flap on *is ype of c*ecC 2al2e s)ings comple ely ou of *e flo) pa *9 Regular c*ecC 2al2e Any par ly close! 2al2e$ or Pump con rol 2al2e$ or Jlobe 2al2e Open ga e 2al2e

3 !iame ers !o)ns ream

- !iame ers !o)ns ream

- !iame ers !o)ns ream ' !iame ers !o)ns ream

, !iame ers !o)ns ream % !iame ers !o)ns ream

.#' !iame ers !o)ns ream

5 !iame ers !o)ns ream

same as @cA

Open bu erfly 2al2e

.#' !iame ers !o)ns ream

5 !iame ers !o)ns ream

( I

Pump !isc*arge O *er

.#' !iame ers !o)ns ream

5 !iame ers !o)ns ream

Please Define

f# T*e plane of an elbo) is angen ial o *e inner ra!ius of *e elbo) as s*o)n in Figure .# No measuremen s )ill be accep e! from *e >one )i *in *e plane$ !efine! by *e ou er limi s of *e plane# An e<ample of *e minimum !is ance re;uire! for a flo) measuremen near an elbo) is illus ra e! in Figure 3#
Outer Limit of Plane Plane of Elbow

Zone "within the plane" No measurements from this zone are accepted

Outer Limit of Plane

Figure .# Defini ion of a @planeA for an elbo)# T*e ou er limi s of *e plane are !efine! by )*ere *e plane *i s *e pipe on ei *er si!e of *e elbo)#
Single Transect NO easurement

D D Plane of Elbow

Double Transect

Figure 3# E<ample of *o) o use *e informa ion# In *is case$ *e flo) measuremen poin is loca e! ups ream of *e elbo) 8case @aA9# ./

g# T*e flo) es me *o! mus be !efine!$ accor!ing o Table 3 belo)# Table 3# Flo) es me *o! i!en ifica ion for Pump Efficiency Repor #
ID for Pump Efficiency Repor A 0 C D E Be *o! "se! for ?eloci y Beasuremen Single Transec ?eloci y Double Transec ?eloci y Propeller Be er "l rasonic Be er O *er 8Please Define9

*# All ransec measuremen s re;uire mul iple 2eloci y poin s in eac* ransec # 1i * a Collins ube$ eac* ransec mus con ain a minimum of 4 poin s 85 on eac* si!e of *e cen erline of flo)9$ eac* of )*ic* represen s *e same cross sec ional area of *e pipe# A (all ube ;ualifies as a @mul iple 2eloci y poin A me er$ an! *erefore only re;uires one 2alue# i# A (all ube mus s*o) a scale balance of less *an .#' for *e pump es er o s a e *a *is measuremen ;ualifies for !ocumen a ion in *e pump repair program# Fiel! !a a summary s*ee s for ul rasonic measuremen !e2ices mus inclu!e !a a on Signal s reng * 8i mus be grea er *an '/ o ob ain an accura e rea!ing# Soun! spee! error# 8T*is is one e<ample of )*a *e pump es er may use as cri eria for s a ing *a *e es sec ion )as ina!e;ua e for an accura e measuremen 9# T*ese are e<amples of con!i ions for )*ic* a es er )ill s a e *a *e resul s canno be guaran ee! o be accura e o )i *in LF+ 4H# 3# Pressure measuremen s# a# Pressures mus be measure! )i * pressure gauges or rans!ucers *a *a2e an accuracy )i *in LF+ .#'H of full scale# b# A pressure gauge s*oul! be selec e! suc* *a *e ac ual pressure rea!ing is in *e mi!!le 8or *ig*er9 of *e gauge range# c# Pressure gauge accuracy mus be 2erifie! as of en as re;uire! o ensure accuracy )i *in LF+ .#'H# 3. Input fue! measurement. a. "ue! #onsumption $i!! %e measure& using an A#taris 'eptune fue! f!o$ meter a##urate to ()* 1 + an& a stop $at#,. At !east - re.o!utions /0.- ga!!ons1 of t,e &ia! $i!! %e measure& an& time& using a stop$at#,. T,e rpm2 f!o$ rate2 an& T34 must %e sta%!e $,en t,e measurement is taken. 4. Engine an& pump spee& measurement. a. Engine spee& $i!! %e measure& using an e!e#troni# ta#,ometer or stro%e !ig,t. %. Pump spee& $i!! %e measure& $it, an e!e#troni# ta#,ometer or stro%e !ig,t. T,e spee& of t,e pump s,aft must %e measure& at eit,er t,e top of t,e gear ,ea& on t,e a&5usting nut2 or t,e s,aft itse!f in t,e &is#,arge ,ea& %e!o$ t,e gear,ea& %ase. #. T,e pump ma6 %e teste& $it, mu!tip!e runs. 4o$e.er2 one #on&ition for t,e test s,a!! %e at a pump s,aft spee& of 17-0*1780 rpm2 $it, norma! &is#,arge #on&itions. ..

-. Statisti#a! &ata regar&ing t,e pump)engine2 as a.ai!a%!e2 $i!! %e re#or&e& using t,e &ata s,eet atta#,e&. 4# To al Dynamic (ea! 8TD(9 compu a ion for O2erall Pumping Plan Efficiency 8OPE9# T*e follo)ing !a a mus be use! o es ima e *e TD( a# For 2er ical pumpsD .9 (eig* of *e pump !isc*arge pressure measuremen poin abo2e *e groun! surface# 39 Dep * from *e groun! surface o *e pumping )a er le2el# 1a"er le#el! i' 9ell! r !u&p! 9ill ,e &ea!ure/ 9i"0 a' elec"ric 9ell ! u'/er; T0e ! u'/er li'e &a* ,e pre&ar2e/ a" i'"er#al! " )acili"a"e "0e &ea!ure&e'"; A cali,ra"e/ air li'e a'/ "e!" pre!!ure (au(e i' "0e accurac* cla!! ) >? &a* al! ,e u!e/ ) r /e"er&i'i'( "0e 9a"er le#el i' 9ell! r !u&p!; 59 Disc*arge pressure$ imme!ia ely a *e pump !isc*arge an! before any 2al2es# -9 Es ima e of column$ inle screen$ an! !isc*arge *ea! losses# I is un!ers oo! *a *e !a a re;uire! o compu e *ese losses may no be a2ailable# (o)e2er$ *ey are in!ee! componen s of *e TD(# T*erefore$ all summary s*ee s gi2en o *e cus omer mus inclu!e one of *e follo)ing s a emen sD a9# @DisclaimerD T*e o2erall pump efficiency is un!eres ima e! because compu a ions !o no inclu!e *e pressure loss in *e column$ screen$ foo 2al2e$ an! !isc*arge *ea! of *e pump#A or b9# @T*e o al pressure loss in *e column$ screen$ foo 2al2e$ an! !isc*arge *ea! of *e pump coul! no be !irec ly measure!# (o)e2er$ *e o al loss is es ima e! o e;ual a o al of NNNNNNNNNNf # 1*en accoun ing for *is$ *e O2erall Pumping Plan Efficiency is NNNNNNNNNN#A b# For *ori>on al pumpsD .9 Inle pressure# 39 Disc*arge pressure$ imme!ia ely a *e pump !isc*arge an! before any 2al2es 59 Ele2a ion !ifference be )een *e inle an! !isc*arge pressure measuremen poin s# C# ?erifica ion of accuracy# For eac* pump es $ *e pump es er mus clearly s a e .# If *e gallons per ac+f is cer ifie! 8by *e pump es er9 o be )i *in LF+ 4H of *e rue 2alue$ an! 3# If *e es represen s s an!ar! opera ing con!i ions for *e pump# D# T*e lis e! re;uiremen s are no all+inclusi2e an! only pro2i!e some minimum re;uiremen s# T*e pump es er is responsible for using all necessary safe y precau ions an! e;uipmen $ an! is responsible for cer ifying *e accuracy of all measuremen s#A

.3

Fuel Flo) Beasuring Sc*ema ic

.5

Appen!i< 3D Pump Tes Resul s$ Oc ober .$ 3//' o Oc ober 5.$ 3//4

8SEE ATTAC(ED E6CEL FILE FOR P"BP TEST RES"LTS9

Appen!i< 5D Pump Re rofi Resul s$ Oc ober .$ 3//' o Oc ober 5.$ 3//4

8SEE ATTAC(ED E6CEL FILE FOR P"BP RETROFIT RES"LTS9

.-

Appen!i< -D E<ample In2oice for a Diesel Pump Repair

Generic Pump Company .//// Bain S ree TULARE, CA 93274 8''%9 4,4+//// Fa< 8S'%9 4,4+////
BILL TOD
Cus omer S:IP TO:

DATE IN?OICE R %F.5F3//'

4/'4

Job Site

.'
PROD"CT .5/4'P "SE 1IT( /5/, MNQIM #OPM

NEBS T Re )/er .+,//+33'+45,/ Of )))#N#com

PAINTE% IN "SA#

.. ~