KURSUS ASAS REKABENTUK SISTEM

PAM PENGAIRAN PERTANIAN

24 26 FEBRUARI 2015
IPMI UTARA
 Objektif Kursus
Memberi pendedahan kepada peserta kursus
tentang pengenalan kepada:

Sistem Pengairan
Sistem Pam Elektrik.
Rekabentuk Pump Sump
Aksesori Pump (will be cover on 25th
February)
 What Is Irrigation?
Application of water to soil by providing it to crop
filled land.
To assist in crop production.
Sustain plant life.
Protecting crops from frost.

Goal: To make land fertile and lush.

Focus : Profitability energy optimization and
better use of water
resources.
 Flood Irrigation
Half of the water applied to the field actually
irrigates the crops and the other half is lost
through evaporation, runoff, transpiration,
weeds, and infiltration of uncultivated areas.
The efficiency of flood irrigation is not very high.
Important concerns :
Distribution uniformity.
Field flooding
Environmental impact of crops.
 Flood Irrigation
Furrow Irrigation
Water is directed or
pumped into a
number of furrows,
which are then
flooded.
Gravity flow channel.
Requires lot of water.
Common irrigation
techniques in tropical
area.
 Modern Pressurised Irrigation

SPRINKEL IRRIGATION DRIP IRRIGATION

Artificial Rain Water and nutrients are

Uniform application. applied directly to the
Two common types: root zone.
Fixed sprinkler Eg: Hydrophonics
Travelling sprinkler Lot of maintenance
clogging.
 Source of Water
Common preception of water - Water was an
infinite resource.
Water resources need to be managed.
Surface water drawn from rivers, canals, lake
or reservoir.
Different source of water different type of
pumps been used.
 Source of Water
Water availability on earth:

3% is fresh or 1% available for use

70% is held in the ice caps
30% is available as groundwater of from lakes
and streams.
 Groundwater
PROS:
Most reliable water source on earth
Correct management is vital
Groundwater measurement are fairly complicated,
because its flow is hidden.

CONS:
Supply limitations
Pump wear
Clogging
Over pumping
 Surface Water
2nd most common source of fresh water.
The most common source in Malaysias
Irrigation activity.
Correct pump levelling / water storage.
Enemy of pumps for surface water:
Mud, silt, organism growth, woods, sand.
 Rainwater
Water source for raining season.
Pumping schedule will stop at this time.
 Pump Station Design

PUMP STATIONS
SYSTEM

ELECTRICAL IRRIGATION
PUMP SYSTEM PUMP SUMP
SYSTEM SYSTEM
 Proses Rekabentuk Sistem Pam
Pengairan
1. Penentuan Kadar Alir
2. Pengiraan Kehilangan Turus (Head Loss
Calculation)
Static Loss
Friction Loss (More applicable when involve piping
system)
3. Pengiraan Head (25 Februari 2015)
4. Sistem Elektrik (26 Februari 2015)
5. Sistem SCADA (26 Februari 2015)
 Penentuan Kadar Alir Pam Saiz Infrastruktur
Pengiraan Kehilangan Sistem Kawalan
Pengiraan Sistem
Turus (Head Loss Elektrik
Curve
Calculation) Aksesori
Matching system and
pump curve
Pemilihan Pam
Tapak Finallize
 Pump Selection
CRUCIAL CRITERIA
Typically been over-sized
Power consumption low
Maintaining system pressure
Adding variable speed control
Motor protection
 Irrigation Pump
CRUCIAL CRITERIA
Availability of water
Type of water
Volume of water
Crops need for water
 Pumps
Pump Definitions
A device which raises or transfer liquids at the
expense of power input.
A machine designed to elevate, deliver and
move various liquids
A unit that transfer the mechanical energy of a
motor or an engine into potential and kinetic
energy of liquid.
 Pump Type
PISTON,
PLUNGER
RECIPROCATING
DIAPHRAGM
DISPLACEMENTS
SINGLE ROTOR
ROTARY
MULTIPLE ROTOR
PUMPS

JET

GAS LIFT
SPECIAL EFFECT
HYDRAULIC RAM

ELECTROMAGNATIC
DYNAMICS

AXIAL FLOW

MIXED FLOW,
CENTRIFUGAL
RADIAL FLOW

PERIPHERAL
 Centrifugal Pump
Centrifugal Pump has a stationary and a
rotating part (impeller).
The impeller has a number of vanes which
force the water to rotate and creates flow.
Stationary part is called pump housing
 Positive Displacement (PD) Pump
The positive displacement pump provides an approximate
constant flow at fixed speed, despite changes in the counter
pressure.
Positive displacement pumps are pulsate, meaning that their
volume flow within a cycle is not constant. The variation in
flow and speed leads to pressure fluctuations due to
resistance in the pipe system and in valves.
 Positive Displacement Pump
1) Reciprocating Pump
Plunger Pumps
Diaphragm Pumps

2) Rotary Pumps
External Gear Pump
Internal Gear Pump
Lobe Pump
Vane Pump
Progressive Cavity Pump
Peripheral Pump
Screw Pump
 PD vs Centrifugal
Flow rate versus pressure
By looking at the
performance chart, the
centrifugal has varying
flow depending on
pressure or head,
whereas the PD pump
has more or less
constant flow
regardless of pressure.
 PD vs Centrifugal
Flow rate versus viscosity
The centrifugal pump
loses flow as the
viscosity goes up but
the PD pumps flow
actually increases. This
is because the higher
viscosity liquids fill the
clearances of the pump
causing a higher
volumetric efficiency.
 PD vs Centrifugal
Efficiency vs Viscosity
Viscosity also plays an
important role in
mechanical efficiency.
Because the centrifugal
pump operates at
motor spefficiency goes
down as viscosity
increases due to
increased frictional
losses within the pump.
PD vs Centrifugal
Screw Pump
 Type Of Screw Pump

Concrete Trough Steel Trough Compact Type

 Screw Pump Body
SCREW PUMP CONSISTS OF:
Screw Pump body Splash Plate
Upper Bearing
Bottom Bearing
Gearbox and Motor
Coupling
Splash Plate

Geared Motor

Top Bearing

Geared Motor Support

 Capacity
The delivered capacity of any screw pump is the theoretical
capacity minus the internal leakage. The capacity of the
pump depends on several factors:

Diameter of the screw

Speed of the screw
Number of flights mounted on the screw shaft
Angle of inclination of the screw (The greater the angle of
inclination, the lower the output. The output lowers
approximately 3% for every degree increase over a 220
inclination.)
Clearance between screw flights and trough
Level of influent in the influent chamber
TP = Touch Point = Angle of inclination H = Discharged
FP = Filling Point D = Tube Diameter Height TP-CP
CP = Chute Point LF = Length of Screw
 Number Of Flights

Angle Of Inclination Of The Screw

 Advatages
Slow speed
Pumps raw water with heavy
solids and floating debris
No collection sump required
Long lifetime
Easy maintenance
Constant high efficiency with
variable capacity
Can run without water
Disadvantages
Release of odors
Relatively high cost because of
close tolerances and running
clearances
Bulky and required space
High pressure capability
requires long pumping
elements
Need good C&S contractor
 Centrifugal Pump
Pam yang paling banyak digunakan di JPS.
3 jenis yang biasa digunakan Radial Flow, Axial
Flow dan Mix Flow.
Axial High flow low head.
Mixed Medium flow medium head.
Radial Low flow high head.
 Hydraulic Submersible
Pump & Power pack

End Suction Pump

Sludge Pump

PAM

Electrical Submersible
Pump & Genset Screw Pump
Axial Flow Pump
Centrifugal Pump
 Water Tight
Junction Cable Entry
box
Sensor
Rotor
Stator
Shaft

Mechanical Seal Bearing

Oil chamber

Propeller
 Impeller
Impeller converts the mechanical rotation to the
velocity of the liquid.
Generally made in casting.
Provided with wearing rings to reduce recirculation
losses and enhance volumetric efficiency.
Smaller size impeller for clean water bronze
Larger size impeller Cast Iron.
Cast Steel Abrasive like ash, sand clinker
Stainless Steel Casting High corrosion resistance
and low temperature application
Aluminium Bronze Marine application
Impellers are dynamically balanced
Impeller types of construction
 Shaft
The prime mover drives the
impeller and displace the
fluid in the impeller and
pump casing through shaft.
During operation, it can be
in tension, compression,
bending, and torsion and
shaft will be likely failed
because of fatigue.
Material carbon steel,
austenitic steel, aluminium
bronze or monel.
 Mechanical Seal
Made of 2 components:
Rotating and Stationary
parts.
Stationary part fixed in the
pump housing.
Rotating part fixed on the
pump shaft.
The 2 primary seals are
pushed against each other by
spring and the liquid
pressure.
Secondary seals prevent
leakage from occurring
between the assembly and
the shaft.
 Bearing
The pump bearing support the
hydraulic load that imposed on
the impeller, the mass of impeller
and shaft, and the load due to
shaft coupling.
Pump bearing keep the shaft axial
end movement and lateral
deflection within acceptable limit
for the impeller and the shaft
seal.
The force on the impeller are
simplified into two component,
axial load and radial load.
 Motor
An electric motor has a
stationary part, the stator, and
a rotating part, the rotor.
The stator is built of laminated
steel plates with slots on the
inner diameter, in which are
inserted copper wire.
The rotor is also built of
laminated steel plates with
slots or holes on the outer
diameter in which are inserted
copper or aluminum bars.
An electric field induced in the
stator forces the rotor to
rotate.
Video Rotor & Stator
 Enclosure Class
The enclosure class states the
degrees of protection of the
motor against ingress of solid
objects and water.
The enclosure class is stated by
means of two letters IP followed
by two digits, for example IP55.
The first digit stands for
protection against contact and
ingress of solid objects and the
second digit stands for
protection against ingress of
water
 Insulation Class
The insulation class tells
something about how
robust the insulation
system is to temperatures.
The life of an insulation
material is highly
dependent on the
temperature to which it is
exposed.
The various insulation
materials and systems are
classified into insulation
classes depending on their
ability to resist high
temperatures.
Motor Start-Up
Centrifugal Pump Video
 Static Losses
Static losses are due to differences in either
elevation or pressure between the inlet and
the discharge.
 Friction Losses
Friction losses occur in the water pipe,
in the elbows, in Ts, in valves, and so
on. The friction loss is dependent on the
flow and is a constant for the device.

It also dependent on the length and the

surface of the pipe. All pipe
manufacturers have their own pipe loss
tables that they make available and
friction loss data can be obtained from
the manufacturer of the equipment.

It is the sum of the friction losses from

all components in an irrigation system
that determines the total friction loss.
 Friction Losses
Pipe friction losses depend on the following
factors:
Pipe Length
Pipe internal diameter
Flow Velocity
Pipe wall relative roughness
Fluid kinematic viscosity.
 Darcy-Weisbach Equation

=

Where :

Hf = Friction Loss, m
F = Friction Factor
L = Pipe length, m
D = Inside Pipe Diameter, m
V = Average Pipe Velocity, m/s
g = Acceleration of gravity, 9.81 m/s
 Hazen-William Equation
= 0.8492 0.63 0.54
Where :
V = Average Pipe Velocity, m/s
C = Friction factor (depends on roughness only)
r = Hydraulic radius (liquid area divided by
wetted perimeter) or D/4 for a full pipe, m
S = Hydraulic Gradient or Frictional Head Loss
per unit length of pipe, m/m
 Curve System

Range Curve

Head, Power Consumption, NPSH Curve

 Curve System
In general pump curves are designed
according to ISO 9906 Annex A, which
specifies the tolerance of the curve:
Q 9%
H 7%
P 9%
7%
 Head (QH Curve)
QH Curve shows the
head, which the
pump is able to
perform at a given
flow.
QH Curve is not
affected by the type
of liquid the pump
has to handle.
 Efficiency -curve
The efficiency is the relation between
the supplied power and the utilised
amount of power.
The efficiency, p is the relation
between the power, which the pump
delivers to water (PH) and the power
input to the shaft (P2):

. . .
= =
2 2

For water at 20oC and with Q

measured in m3/h and H in m, the
hydraulic power can be calculated as :

= 2.72. . [W]
 Power Consumption P2 - Curve
The relation between the power consumption
of the pump and the flow is shown beside:
The P2 value increases when the flow increases.
 NPSH-Curve
(Net Positive Suction Head)
The NPSH value of a pump is the minimum
absolute pressure that has to be present at the
suction side of the pump to avoid cavitation.
 Curve System
The system curve by
definition starts at
zero and goes
through the pumps
duty point on the
pump curve.
 Net Positive Suction Head,NPSH
NPSH describes conditions related to cavitation.
Cavitation should always be avoided as it causes
inefficient and is harmful to the installation.
NPSH value is absolute and always positive.
NPSHA stands for NPSPH Available and express
how close the fluid in the suction pipe is to
vaporization.
NPSHR stands for NPSH Required and describes
the lowest NPSH Value required for acceptable
operating conditions.
 Net Positive Suction Head,NPSH
NPSH formula:
NPSHA = Hb NPSHR - Hf Hv Hs
Hb Atmospheric pressure @ pump site
Hf - Friction loss in the pipe
Hv Vapor pressure of the liquid
Hs - Safety factor (0.5 m and 1 m)
NPSHR Net Positive Suction Head Required

NPSHA NPSHR
 NPSH
NPSHA = Hb NPSHR - Hf Hv Hs
 Vapor Pressure
Water boils at 100C, although
this is only true as long as the
atmospheric pressure is
normal. When the pressure
drops below the atmospheric
pressure, water will boil at
much lower temperatures.
As an example, if the pressure
drops to 0.1 bar, water will
start boiling already at 45C.
The atmospheric pressure is
also lower at higher elevation.
This phenomenon becomes
an important issue when
working with pumps.
 Cavitation
Cavitation occurs somewhere in a pump when
the pressure is lower than vapour pressure.
Cavitation is the creation of vapor bubbles in
areas where the pressure locally drops to the
fluid vapor pressure.
Noise and vibration will occurs.
 CAVITATION
Cavitation is a phenomenon
caused by the water boiling.
Cavitation can be heard as a
loud noise and vibration, and it
is devastating for the pump.
It is when the water is changing
its state from vapor to water
that the damage occurs. The
vapor bubbles in the water
implode causing noise, and
followed by a heavy mechanical
impact, which will destroy the
pump if cavitation takes place
over an extended period.
Cavitation
 Cavitation
When the vapour pressure on the suction side
drops below the vapour pressure of the liquid,
small bubbles form. These bubbles collapse when
the pressure rises and release shock waves.
 Cavitation
Consequently, impellers can be damage to the impeller depends on the properties
of the material.
Cavitation decreases flow (Q) and head (H), which leads to reduced pump
performance .
Damage due to cavitation is often only detected when the pump is dismantled.
Furthermore, cavitation results in increased noise and vibrations, which can
consequently damage bearings, shaft seals and weldings.
 Cavitation
How to compensate the destruction and avoid cavitation is
by increasing the inlet pressure.
Lower the inlet and reduce the suction lift.
Reduce friction loss in the suction pipe.
Reduce the flow.
Lift the suction water level.
Cavitation Video
 Adverse Hydraulic Phenomena

Excessive pre-swirl
Change flow conditions
Change in pump
performance
Bearing wear
Cavitation across impeller

Uneven velocity distribution

 Entrained air
Minor air entrainment
will lead to a clear
reduction in pump
performance and loss
of efficiency; the
severity depends upon
the quantity of air
entrained and the
pump type.
 Vortices
Vortex is a region within a fluid where the flow
is mostly a spinning motion.
Vortices are a result of flow, speed and pressure
and can be formed from the surface when the
water level is too low and also can be formed
submerged from the back or side wall or from
the floor.
Vortices
 Vortex

Vortex occur beside

pump column
Vortex Video
 Pump Station Design

PUMP STATIONS
SYSTEM

ELECTRICAL IRRIGATION
PUMP SYSTEM PUMP SUMP
SYSTEM SYSTEM
Pump Sump Design
 Pump Sump
Inlet
An inlet directs water to the
pumping station from supply
source.
Forebay
Serves to create a uniform and
steady flow to the pump bays.
Pumbay
Pump location. Once the water
flow through the pumps bay
and reaches the pump inlet, it
must be uniform and without
swirls and entrained air.
 Pump Sump Design

Pump relies on
Uniform Flow
Crucial impact on intakae structure
Free of vortices
Good Sump Design the pumps total to achieve their
No excessive
lifespan. optimum hydraulic
swirls
performance.
 Pump Sump Design

Lead to
Vibration,
Poor Sump Poor sedimentation
Noise &
Design performance of sand and
Cavitation
rags
 Water Velocity
Appropriate water velocity is essential for the
reliability and the efficiency of a pumping
station.
To avoid sedimentation and build up of
obstructions it is important to maintain
sufficient velocity.
It also important to keep the velocity low
enough to prevent pressure losses and
vortices in the pump bay.
 Velocity Guidelines
Bottom inclination - 10 to 15 degrees.
Inlet channel < 1.2 m/s
Pumping station 0.3 ~ 0.5 m/s
Cross flow < 0.5 m/s
 Pump Sump Design
The following phenomena should be prevented or reduced to a minimum in a
properly designed pump sump:

Non-uniform flow at the pump intake:

Results in excessive noise and vibrations, and reduced efficiency
Unsteady flow:
Can cause fluctuating loads
Swirl in the intake:
Can create vortices and unwanted changes to the head, flow, efficiency and
power
Submerged vortices:
Can cause discontinuities in the flow and can lead to noise, vibration and local
cavitation
Surface vortices:
Can draw harmful air and floating debris into the pump
Entrained air:
Can reduce the flow and efficiency, causing noise, vibration, fluctuations of load,
and result in damage to the pump.
 Computational Fluid Dynamics (CFD)
CFD can be used to depict
accurately fluid flows and
pressure graphically an any
location in the system.
Simulate & discover flow
problems correct them
before construction begins.
Provide design alternatives
to stakeholders.
CFD
CFD Video
Model Testing
RUMAH PAM SG. KERIAN (BOGAK)
RUMAH PAM SG. KERIAN (BOGAK)