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Restructuring and Diversification<br />

Management Unit (RDMU)<br />

to coordinate the implementation of<br />

the National Adaptation Strategy to<br />

the EU Sugar Reform, <strong>Swaziland</strong><br />

<strong>Service</strong> <strong>Contract</strong> <strong>No</strong> <strong>2007</strong> / <strong>147</strong>-<strong>446</strong><br />

EuropeAid/125214/C/SER/SZ: Restructuring and<br />

Diversification Management Unit to coordinate the<br />

implementation of the National Adaptation Strategy to the<br />

EU Sugar Reform, SWAZILAND<br />

EC General Budget – SU-21-0603<br />

SWAZILAND Technical Audit of <strong>Farmers</strong> Association<br />

M a v e l a F a r m e r s A s s o c i a t i o n<br />

Submitted to:<br />

The Delegation of the European Commission to <strong>Swaziland</strong><br />

4 th Floor Lilunga House, Somhlolo Road, Mbabane, <strong>Swaziland</strong><br />

Ministry of Economic Planning and Development<br />

P.O. Box 602<br />

Mbabane H100, <strong>Swaziland</strong>


Your contact persons<br />

with GFA Consulting Group GmbH are<br />

Dr. Susanne Pecher<br />

Anke Schnoor<br />

Restructuring and Diversification Management Unit<br />

(RDMU)<br />

to coordinate the implementation of the National Adaptation<br />

Strategy to the EU Sugar Reform, <strong>Swaziland</strong><br />

Technical Audit of <strong>Farmers</strong> Association<br />

Authors: Tiekie de Beer<br />

&<br />

Bongani Bhembe<br />

Mission Report<br />

Address<br />

GFA Consulting Group GmbH<br />

Eulenkrugstraße 82<br />

D-22359 Hamburg<br />

Germany<br />

Phone +49 (40) 6 03 06 – 111<br />

Fax +49 (40) 6 03 06 - 119<br />

Email: afrika@gfa-group.de<br />

<strong>Mavela</strong> Farmer Association Report - 2009<br />

Page ii


DISCLAIMER<br />

The contents of this report are the sole responsibility of the RDMU and can in no way<br />

be taken to reflect the view of the European Union.<br />

<strong>Mavela</strong> Farmer Association Report - 2009<br />

Page iii


TABLE OF CONTENTS<br />

TABLE OF CONTENTS ................................................................................................................................. iv<br />

LIST OF TABLES ............................................................................................................................................ vi<br />

LIST OF FIGURES ......................................................................................................................................... vii<br />

LIST OF APPENDICES ................................................................................................................................ viii<br />

ABBREVIATIONS ........................................................................................................................................... ix<br />

1 INTRODUCTION ............................................................................................... - 1 -<br />

2 BACKGROUND ON IRRIGATION DEVELOPMENT ....................................... - 2 -<br />

3 TECHNICAL AUDIT REPORT ..........................................................................- 3 -<br />

3.1.1 REVIEW OF THE IRRIGATION DESIGN CRITERIA AND SPECIFICATIONS .........................- 3 -<br />

3.1.1.1 Irrigation Design and Specifications by the contractor ..............................................................- 3 -<br />

3.1.1.1.1 DESIGN CRITERIA ............................................................... Error! Bookmark not defined.<br />

3.1.1.1.2 LAYOUT ................................................................................. Error! Bookmark not defined.<br />

3.1.1.1.3 PUMP UNIT ............................................................................ Error! Bookmark not defined.<br />

3.1.1.1.4 STARTER AND ELECTRICAL CONNECTION .................. Error! Bookmark not defined.<br />

3.1.1.1.5 SUCTION AND DELIVERY FITTINGS ............................... Error! Bookmark not defined.<br />

3.1.1.1.6 MAINLINE .............................................................................. Error! Bookmark not defined.<br />

3.1.1.1.7 HYDRANTS ............................................................................ Error! Bookmark not defined.<br />

3.1.1.1.8 PORTABLE SPRINKLER EQUIPMENT .............................. Error! Bookmark not defined.<br />

3.1.1.1.9 IRRIGATION LATERALS ..................................................... Error! Bookmark not defined.<br />

3.1.1.2 Review of <strong>Contract</strong>or Irrigation Design Criteria and Specifications .........................................- 3 -<br />

3.1.1.2.1 Planning ................................................................................................................................- 3 -<br />

4 FIELD EVALUATION OF IRRIGATION SYSTEM ..........................................- 12 -<br />

4.1.1 Pumps And Pump Stations ...............................................................................................................- 12 -<br />

4.1.1.1 Pump Suction Side ...................................................................................................................- 12 -<br />

4.1.1.1.1 Suction Pipe Flow Rate .......................................................................................................- 12 -<br />

4.1.1.1.2 Requirements for Fittings ...................................................................................................- 13 -<br />

4.1.1.1.3 Suction Pipe Inlets ..............................................................................................................- 16 -<br />

4.1.1.1.4 Suction side losses ..............................................................................................................- 19 -<br />

4.1.1.1.5 Suction height .....................................................................................................................- 19 -<br />

4.1.1.2 Pump evaluation .......................................................................................................................- 21 -<br />

4.1.1.2.1 Power required on the pump shaft ......................................................................................- 21 -<br />

4.1.1.2.2 Pump Operation ..................................................................................................................- 22 -<br />

4.1.1.2.3 General ................................................................................................................................- 24 -<br />

4.1.2 Power Supply And Consumption .....................................................................................................- 26 -<br />

4.1.3 Supply System ..................................................................................................................................- 29 -<br />

4.1.3.1 Mainline size ............................................................................................................................- 29 -<br />

4.1.3.2 Mainline class ..........................................................................................................................- 30 -<br />

5 FIELD EVALUATION OF SPRINKLER IRRIGATION SYSTEM .................... - 31 -<br />

5.1 Pressure readings ................................................................................................................................- 32 -<br />

5.1.1 Pressure at hydrant ............................................................................................................................- 32 -<br />

5.1.2 Sprinkler pressure .............................................................................................................................- 33 -<br />

5.2 Delivery tests ........................................................................................................................................- 38 -<br />

5.2.1 Sprinkler discharge ...........................................................................................................................- 38 -<br />

<strong>Mavela</strong> Farmer Association Report - 2009<br />

Page iv


5.3 Distribution tests .................................................................................................................................- 41 -<br />

5.3.1 Importance of CU and DU ..................................................................... Error! Bookmark not defined.<br />

5.3.2 Christiansen’s uniformity coefficient (CU): .......................................... Error! Bookmark not defined.<br />

5.3.3 Distribution uniformity (DU): ............................................................... Error! Bookmark not defined.<br />

5.3.4 Application efficiency (AE): ................................................................. Error! Bookmark not defined.<br />

6 ASSESSMENT OF OPERATION, MANAGEMENT AND MAINTENANCE OF<br />

THE IRRIGATION SYSTEM .................................................................................. - 42 -<br />

6.1 Operation .............................................................................................................................................- 42 -<br />

6.2 Management Practices ........................................................................................................................- 45 -<br />

6.3 Maintenance Survey ...........................................................................................................................- 45 -<br />

6.4 Observations ................................................................................................. Error! Bookmark not defined.<br />

7 CONSTRAINTS TO EFFICIENT SYSTEM PERFORMANCE ........................- 47 -<br />

8 RECOMMENDATIONS ...................................................................................- 51 -<br />

9 CONCLUSION ................................................................................................- 54 -<br />

10 LITERATURE REFERENCES .....................................................................- 55 -<br />

11 PRODUCT INFORMATION .........................................................................- 59 -<br />

12 APPENDICES .............................................................................................- 65 -<br />

<strong>Mavela</strong> Farmer Association Report - 2009<br />

Page v


LIST OF TABLES<br />

TABLE 1. PUMP AND MOTOR SPECIFICATIONS AND MEASUREMENTS CONDUCTED ON ALL PUMPS .............. - 21 -<br />

TABLE 2. RIVER PUMPS EVALUATION ................................................................................................................ - 23 -<br />

TABLE 3. OPTIMAL OPERATING PRESSURE VS NOZZLE DIAMETER FOR SPRINKLERS ........................................ - 33 -<br />

TABLE 4. PRESSURE AND NOZZLE SIZE MEASUREMENTS RESULTS .................................................................... - 36 -<br />

TABLE 5. DISCHARGE VARIATION CALCULATED FROM FIELD MEASUREMENTS ................................................ - 39 -<br />

TABLE 6.TECHNICAL PROPERTIES OF SPRINKLERS FOUND ON SITE AT 35M OPERATING PRESSURE ................ - 40 -<br />

TABLE 7. MAINTENANCE SCHEDULE FOR SPRINKLER IRRIGATION SYSTEMS ..................................................... - 45 -<br />

TABLE 8. MAINTENANCE PRACTICES IMPLEMENTED BY MAVELA FA ................................................................ - 46 -<br />

<strong>Mavela</strong> Farmer Association Report - 2009<br />

Page vi


LIST OF FIGURES<br />

FIGURE 1. MAVELA INTAKE SUMP ALONG THE MBULUZI RIVER ......................................................................... - 2 -<br />

FIGURE 2. SAPWAT SCREEN INDICATING WATER REQUIREMENT FOR SPRINKLER IRRIGATION WITH RAINFALL<br />

TAKEN INTO ACCOUNT ................................................................................................................................ - 7 -<br />

FIGURE 3. REQUIRED RADIUS OF 90 BENDS (SOURCE: ARC (<strong>2007</strong>)) .................................................................. - 13 -<br />

FIGURE 4. 45° AND 90° BENDS ON RIVER PUMP SUCTION MANIFOLD ............................................................. - 14 -<br />

FIGURE 5. CONCENTRIC AND ECCENTRIC REDUCERS ......................................................................................... - 14 -<br />

FIGURE 6. CORRECT INSTALLATION OF ECCENTRIC REDUCERS ......................................................................... - 15 -<br />

FIGURE 7. CORRECT INSTALLATION OF ECCENTRIC REDUCERS ON ONE OF THE PUMPS .................................. - 16 -<br />

FIGURE 8. SPACING AND PLACING OF SUCTION PIPE INLETS............................................................................. - 17 -<br />

FIGURE 9. MAVELA INTAKE SUMP ALONG THE MBULUZI RIVER ....................................................................... - 17 -<br />

FIGURE 10. CLEANING OF THE INTAKE SUMP ALONG A HIGH FLOWING MBULUZI RIVER ................................ - 18 -<br />

FIGURE 11. MINIMUM WATER DEPTH ABOVE SUCTION PIPE INLET ................................................................. - 18 -<br />

FIGURE 12. ATMOSPHERIC PRESSURE VS. HEIGHT ABOVE SEA LEVEL ............................................................... - 20 -<br />

FIGURE 13. INSIDE MAVELA PUMP STATION ..................................................................................................... - 24 -<br />

FIGURE 14. MALFUNCTIONING DRAINAGE PUMP ............................................................................................. - 25 -<br />

FIGURE 15. LATERAL HYDRANT VALVE ............................................................................................................... - 32 -<br />

FIGURE 16. PRESSURE MEASUREMENT WITH A PITOT TUBE END PRESSURE GAUGE ............ - 34 -<br />

FIGURE 17. POSITIONS OF COMPLETE SPRINKLER PRESSURE MEASURES IN AN IRRIGATION BLOCK ............... - 35 -<br />

FIGURE 18. MEASURING APPARATUS FOR SPRINKLER NOZZLE SIZE ................................................................. - 37 -<br />

FIGURE 19. MAVELA FA SUGARCANE ABOVE RECOMMENDED TESTING HEIGHT ............................................. - 41 -<br />

FIGURE 20. MAVELA WEED INFESTED SUGARCANE ........................................................................................... - 43 -<br />

<strong>Mavela</strong> Farmer Association Report - 2009<br />

Page vii


LIST OF APPENDICES<br />

Appendix 1: SEB usage for river pump station phase 2<br />

Appendix 2: capital recovery factors (CRF)<br />

Appendix 3: soil map and block layout<br />

<strong>Mavela</strong> Farmer Association Report - 2009<br />

Page viii


ABBREVIATIONS<br />

Abbreviation<br />

AE<br />

ARC<br />

ASAE<br />

CU<br />

CV<br />

DU<br />

EAC<br />

EU<br />

FA<br />

GAR<br />

HDPE<br />

MCC<br />

NAR<br />

NPSH<br />

PVC<br />

RSSC<br />

SABI<br />

SE<br />

SSA<br />

SWADE<br />

Us<br />

Description<br />

Application Efficiency<br />

Agricultural Research Council<br />

American Society of Agricultural Engineers<br />

Christiansen’s uniformity coefficient<br />

Coefficient of Variation<br />

Distribution Uniformity coefficient<br />

Equivalent Annual Cost<br />

Emitter Uniformity<br />

<strong>Farmers</strong> Association<br />

Gross Application Rate<br />

High Density Polyethylene<br />

Motor Control Centre<br />

Net Application Rate<br />

Net Positive Suction Head<br />

Polyvinyl Chloride<br />

Royal <strong>Swaziland</strong> Sugar Corporation<br />

South African Irrigation Institute<br />

System Efficiency<br />

<strong>Swaziland</strong> Sugar Association<br />

<strong>Swaziland</strong> Water & Agricultural Development Enterprise<br />

Statistical Uniformity<br />

<strong>Mavela</strong> Farmer Association Report - 2009<br />

Page ix


1 I N T R O D U C T I O N<br />

Association general information<br />

1. Farm name: Swazi Nation Land<br />

2. Name of Association: <strong>Mavela</strong> <strong>Farmers</strong> Association<br />

3. Location:<br />

Latitude 61 000.00<br />

Longitude 2 895 200.00<br />

Altitude 310<br />

Maximum Temperature 36<br />

Minimum Temperature 8<br />

4. Postal address: 86 Tshaneni<br />

5. Contact Details:<br />

Chairman – Mr. E. Ndzimandze 605 8957<br />

Farm Supervisor- Mr. Magagula 611 8110<br />

6. Area of farm (ha) 62.4<br />

7. Crops irrigated: Sugarcane<br />

8. Designers name and details: G4 Farm and Estate Development<br />

9. Date of evaluation: 16 February 2009<br />

10. Evaluators: Tiekie de Beer and Bongani Bhembe<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 1 -


2 B A C K G R O U N D O N I R R I G A T I O N<br />

D E V E L O P M E N T<br />

<strong>Mavela</strong> <strong>Farmers</strong> Association’s irrigation system of 62.4 ha was designed and installed by G4<br />

Farm and Estate Development in two phases. The first phase was 50.2 ha and was<br />

commissioned in 1998; the second phase was completed in 2000 and was 12.4 ha. The<br />

designer was Mr. Kennedy Dlamini.<br />

2 . 1 T h e p r o j e c t<br />

‣ The entire project is a dragline irrigation system with a 54m lateral spacing and 18m<br />

draglines.<br />

‣ The project consists of one intake sump and one pump station housing two KSB pumps<br />

along the Mbuluzi River.<br />

Figure 1. <strong>Mavela</strong> intake sump along the Mbuluzi River<br />

‣ Phase two was an extension of phase 1 and an extra pumping unit was installed<br />

‣ Each lateral is isolated by a Bermad hydraulic valve with a mechanical choke for pressure<br />

regulation.<br />

‣ The sprinklers are not equipped with sprinkler pressure regulators which are necessary<br />

with the type of topography of this project.<br />

‣ The Motor Control Centres (MCC) of all pump stations are well designed and installed.<br />

‣ The project is developed on two soil sets the L and B sets<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 2 -


3 T E C H N I C A L A U D I T R E P O RT<br />

3.1.1 R E V I E W O F T H E I R R I G A T I O N D E S I G N C R I T E R I A<br />

A N D S P E C I F I C A T I O N S<br />

3.1.1.1 Irrigation Design and Specifications by the contractor<br />

Design information from the designer and from the client’s representative during construction,<br />

Ubombo sugar, could not be obtained. The design was therefore checked against <strong>Swaziland</strong><br />

Sugar Industry Standard and SABI norms shown below.<br />

3.1.1.1.1 DESIGN CRITERIA<br />

Crop<br />

Area under irrigation<br />

Gross Application<br />

Net Application<br />

Irrigated Cycle<br />

Sprinkler discharge<br />

Sprinkler Spacing<br />

Precipitation Rate<br />

Stand time<br />

Annual Irrigation hours<br />

Sugar Cane<br />

62.4Ha<br />

52mm<br />

39 mm per cycle (6.5 mm/day)<br />

6/7 days (depending on soil type)<br />

0.39 l/s<br />

18m x 18m<br />

4.3mm/hr<br />

12 hours (depending on soil type)<br />

3 300 hours<br />

3.1.1.2 Review of <strong>Contract</strong>or Irrigation Design Criteria and Specifications<br />

3.1.1.2.1 Planning<br />

Of the four major input of planning namely crop, climate, soil and irrigation system, the study<br />

revealed that crop and climate information used as supplied by the SSA (<strong>Swaziland</strong> Sugar<br />

Ass) Soil types were not taken into consideration during design and or implementation of the<br />

project.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 3 -


Attached in annexes is field Map 1, a soil map of <strong>Mavela</strong> FA indicating the two major soil<br />

types on which the project was developed. The contractor’s tender document where it states<br />

what drawings were issued to the contractor makes it is clear that the soil map was not given<br />

to the contractor but a schematic field layout and bulk water supply.<br />

The purpose of this study was to determine the quantity of water required by the crops per<br />

cycle during peak demand periods and how often it was to be applied taking practical<br />

operating practice into account.<br />

Taking soils into account the following planning schedule was developed:<br />

Peak Design-<strong>No</strong>rm For Sprinkler Irrigation At <strong>Mavela</strong> F A<br />

1 GENERAL INFORMATION<br />

1,1 Owner <strong>Mavela</strong> F A<br />

1,2 Farm Name - Number - Co-ordinates Swazi nation land<br />

1,3 Telephone number<br />

1,4 Area developed<br />

1,5 Water Allocation<br />

2 CLIMATE<br />

2,1 Month state Jan<br />

2,2 Weather station state Ubombo<br />

2,3 Evaporation mm/day 7mm A-Pan or 5mm Grass Factor<br />

3 MANAGEMENT<br />

3,1 Available working days per week days 7<br />

3,2 Available working Hours per day hours 24<br />

4 CROP BLOCK NO Lesibovu<br />

4,1 Type state Sugar<br />

4,2 Area Ha 20<br />

4,3 Plant spacing m NA<br />

4,4 Row spacing m 1.8<br />

4,5 Effective root depth m 0.45<br />

4,6 Plant time date August<br />

5 SOIL Lesibovu<br />

5,1 Effective soil depth m 1<br />

5,2 Water holding capacity mm/m 180<br />

5,3 Easy available water (10-50 kPa) 50% mm/m 90<br />

5,4 Easy available water in root zone mm 40.5<br />

6 WATER<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 4 -


6,1 C en S Classification of water C+S Usuto River<br />

7 EMITTER<br />

7,1 Type type Vyrsa 70 Vyrsa 70<br />

7,2 <strong>No</strong>zzle size mm 11/64 11/64<br />

7,3 Discharge l/h 1390 1390<br />

7,4 Working pressure kPa 350 350<br />

7,5 Application efficiency % 70 70<br />

7,6 Emitter spacing m 18 18<br />

7,7 Lateral spacing m 18 18<br />

7,8 Wetted diameter m 36 36<br />

7,9 Gross Application rate on wetted area mm/h 4.29 4.29<br />

7,10 Nett Application rate on wetted area mm/h 3.33 3.33<br />

8 SCHEDULING<br />

8,1 Crop factor (max) max 1.15 1.15<br />

8,2 Evaporation mm/day 5 5<br />

8,3 Evapotranspiration mm/day 5.75 5.75<br />

8,4 Net Irrigation requirement mm/day 5.75 5.75<br />

8,5 Gross Irrigation requirements mm/day 6.04 6.04<br />

8,6 Theoretical cycle length day 7.04 3.13<br />

8,7 Theoretical Stand time hour 12.16 5.40<br />

8,8 Practical Cycle length day 6 3<br />

8,9 Practical Stand time hours 12 6<br />

8,10 Working days per week days 7 7<br />

8,11 Irrigation hours per day hours 24 24<br />

8,12<br />

Gross application rate per practical<br />

cycle mm 51.48 25.74<br />

8,13 Gross application per month mm 220.62 257.40<br />

9 SCHEDULE OF BLOCKS THAT IRRIGATE TOGETHER<br />

10 HYDRAULICS<br />

10,1 Pressure difference over block m 40 40<br />

10,2<br />

Pressure at beginning of sub main or<br />

lateral m 40 40<br />

10,3 Velocity in mainline (max) m/s 1 1<br />

PRACTICAL STAND TIME / START TIME<br />

11 for 6 Day Cycle length<br />

Start End<br />

11,1 Position 1<br />

Day 1<br />

06,00 Day 1 18,00<br />

11,2 Position 2<br />

Day 1<br />

18,00 Day 2 06,00<br />

11,3 Position 3<br />

Day 2<br />

06,00 Day 2 18,00<br />

11,4 Position 4<br />

Day 2<br />

18,00 Day 3 06,00<br />

11,5 Position 5<br />

Day 3<br />

06,00<br />

Day 3<br />

18,00<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 5 -


11,6 Position 6<br />

11,7 Position 7<br />

11,8 Position 8<br />

11,9 Position 9<br />

11,10 Position 10<br />

11,11 Position 11<br />

11,12 Position 12<br />

11,13 Position 1 start at beginning again<br />

Day 3 Day 4<br />

18,00 06,00<br />

Day 4<br />

06,00 Day 4 18,00<br />

Day4<br />

18,00 Day 5 06,00<br />

Day 5<br />

06,00 Day 5 18,00<br />

Day 5<br />

18,00 Day 6 06,00<br />

Day 6 Day06<br />

06,00 18,00<br />

Day 6 Day 7<br />

18,00 06,00<br />

Day 8<br />

06,00<br />

12 FILTER<br />

12,1 Type State<br />

12,2 Total total<br />

12,3 Filtration size micron<br />

12,4 Pressure loss over filter (clean) m<br />

12,5 Pressure lose over filter (dirty) m<br />

13 DESIGNER<br />

13,1 Name Tiekie de Beer<br />

13,2 Company Tiekie de Beer Consulting<br />

13,3 SABI Membership Designer Fellow<br />

Climatic information:<br />

Climatic information used when compiling the above schedule was obtained from SAPWAT<br />

and a summary of which is shown by the figures below.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 6 -


Figure 2. SAPWAT screen indicating water requirement for sprinkler irrigation with<br />

rainfall taken into account<br />

Soil information<br />

Soil properties used when compiling the aforementioned schedule was obtained from the<br />

below charts. These are the two major soils found within the farm, an outline of which is<br />

shown on a soil map attached in annexes.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 7 -


<strong>Mavela</strong> Farmer Association Report - 2009 Page - 8 -


<strong>Mavela</strong> Farmer Association Report - 2009 Page - 9 -


<strong>Mavela</strong> Farmer Association Report - 2009 Page - 10 -


<strong>Mavela</strong> Farmer Association Report - 2009 Page - 11 -


4 F I E L D E V A L U A T I O N O F I R R I G A T I O N<br />

S Y S T E M<br />

4.1.1 P u m p s a n d P u m p S t a t i o n s<br />

4.1.1.1 Pump Suction Side<br />

The majority of problems occurring with pumps are usually the result of poor suction side<br />

design and installation. The installation and design of the suction side must ensure that<br />

turbulence occurring in the suction pipe and collection of air in high places in the suction pipe,<br />

is prevented. In view of the above, the different suction side components were evaluated.<br />

4.1.1.1.1 Suction Pipe Flow Rate<br />

The suction pipe flow velocity of river and booster pumps was calculated as follows:<br />

353,68 Q<br />

V m / s<br />

2<br />

d<br />

……………………….… (1)<br />

Where: V = flow velocity in pipe (m/s)<br />

Q = flow rate (m³/h)<br />

d = inner diameter of suction pipe (mm).<br />

The design duty point both pumps is not known and for the purposes of the evaluation pump<br />

discharge was estimated by the multiplying of the total irrigated area (62.4 ha), industry<br />

norms of 2.57 sprinklers per hectare (for a 6 day cycle), 1.4m³/hr sprinkler discharge and 10%<br />

safety factor for pump discharge. The two pumps in this pump station must therefore<br />

generate 247m³/hr of flow to meet irrigation requirements.<br />

Based on equation one above the flow velocity at this pump discharge through the 250mm<br />

main suction manifold is duty point through the suction manifold is 1.46 m/s. From the main<br />

manifold a Y piece was constructed to the inlets of the two pumps. One leg of this one piece<br />

is 250mm and the other leg 200mm. The ETA 125-50/2 pump was installed with the first<br />

phase of 50.2 ha and flow through this section is 198.7m³/hr. Theoretically, these two legs<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 12 -


have a flow velocity of 1.17 and 0.4 m/s respectively and there is not much deviation from<br />

these figures when half the total system flow is assumed to be generated by each pump.<br />

Flow velocities through the suction manifold are below the recommended maximum.<br />

According to the Agricultural Research Council, ARC (<strong>2007</strong>) the ideal suction pipe flow<br />

velocity must be 1.0 m/s, but suction pipe flow velocities up to 1.5 m/s are acceptable. A<br />

conclusion was therefore drawn that this pump house was designed correctly and the<br />

evaluated pump is operating optimally.<br />

4.1.1.1.2 Requirements for Fittings<br />

90º Bends<br />

The radius (mm) of a 90º bend must be, at least, as shown in Figure3<br />

r<br />

d<br />

Figure 3. Required radius of 90 bends (source: ARC (<strong>2007</strong>))<br />

r 2d<br />

100<br />

mm<br />

…………………………………... (2)<br />

Where: r = radius of bend (mm)<br />

d = inner diameter of suction pipe (mm).<br />

Two 250mm 90° bends and one 250mm 45° bend was installed on the main suction manifold.<br />

The delivery manifolds from the two pumps has a total of two bends, a 45° and a 90° 150mm<br />

bend, inside the pump station. The radius of 250mm and 150mm bends are 275mm and<br />

190mm respectively. According to figure 4 and equation 2 above the required minimum are<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 13 -


500 and 400mm respectively. There is more than five time the suction and delivery pipe size<br />

diameter pipe further on from these bends, hence the effects of the incorrect sizes were<br />

insignificant.<br />

Figure 4. 45° and 90° bends on river pump suction manifold<br />

Reducers<br />

The inlet on the pump suction side must be eccentric with the straight side towards the top, to<br />

prevent air collecting in the suction pipe and causing cavitation (ARC, 2006). The length of<br />

both eccentric and concentric reducers were evaluated against equation 3 (figure 5) below,<br />

adopted from the ARC.<br />

Figure 5. Concentric and eccentric reducers<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 14 -


( d ) ………………………... (3)<br />

5<br />

2<br />

d1<br />

Where: = length of the reducer (mm)<br />

d1 = smaller inner diameter (mm)<br />

d2 = larger inner diameter (mm)<br />

A 125-200 eccentric reducer was installed on the suction side of pump ETA 100-50/2 and a<br />

150-250 eccentric reducer installed on the second pump, ETA 125-50/2. The delivery<br />

manifolds of these two pumps are of different sizes. Pump 1 manifold is attached to a 100-<br />

150mm concentric reducer and pump 2 is attached to a 125-200 concentric reducer. These<br />

reducers are installed as per the requirement but are of unacceptable dimensions. The<br />

eccentric reducer was installed with the straight side towards the top, to prevent air collecting<br />

in the pipe and concentric reducers on the delivery pipe (figure 6).<br />

The unacceptable dimensions of the concentric reducer had negligible effects on the<br />

performance of the pump and the entire system. The concentric reducer on the other hand is<br />

directly attached to the pump and the sudden restriction in size increases turbulence<br />

occurrences and cause irregular feeding of the pump hence cavitation. With such an<br />

installation wearing and maintenance cost of the pump would increase.<br />

Figure 6. Correct installation of eccentric reducers<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 15 -


Figure 7. Correct installation of eccentric reducers on one of the pumps<br />

4.1.1.1.3 Suction Pipe Inlets<br />

Spacing and placing of suction pipe inlets<br />

The inlet of the suction pipe was not installed in accordance to the requirements of at least<br />

0,5d (d = inner diameter of the suction pipe) from the bottom of the pump sump (figure 8).<br />

The requirement that the suction pipe must be of at least 1,5d away from the side of the<br />

pump sump was not met here.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 16 -


d<br />

1.5d<br />

0.5d<br />

d<br />

3d 3d 1.5d<br />

Figure 8. Spacing and placing of suction pipe inlets<br />

An intake sump was constructed in 2002 after experiencing recurrent mechanical problems<br />

with their pumps. Measurements taken from this sump reflected that the requirements as<br />

shown in figure 8 above were not met. The foot valve is at least 100mm from the bottom of<br />

the sump, instead of 125mm and the suction pipe is about 500 and 600mm from the walls of<br />

the sump, instead of 750mm. The suction pipe is not permanently anchored onto the sump<br />

and can be adjusted to these requirements.<br />

Figure 9. <strong>Mavela</strong> intake sump along the Mbuluzi River<br />

The alignment of this sump in relation to the stream flow enables sand to be deposited inside<br />

the sump. In fact, when the river level is high <strong>Mavela</strong> loses irrigation time while cleaning the<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 17 -


sand out of the sump. This can take up to a week and has to be corrected. During the dry<br />

season sand bags are used to divert water from almost the centre of the river.<br />

Figure 10. Cleaning of the intake sump along a high flowing Mbuluzi river<br />

The minimum water depth above suction pipe inlet depends on the suction pipe velocity and<br />

was evaluated using the graph shown in figure 11 below. Site investigation revealed a water<br />

depth of approximately 1.2m and with a maximum velocity of 1.46m/s the depth should be at<br />

least 0.8m. With the recommended velocities this depth is acceptable. At the minimum river<br />

level water depth decrease substantially.<br />

Figure 11. Minimum water depth above suction pipe inlet<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 18 -


Foot valves<br />

The area around the foot valves was clean and the total area of the openings from the suction<br />

sieve was more than the minimum ARC requirement of 1.5 times larger than the crosssectional<br />

area of the suction pipe to prevent partial blockages of the suction sieve.<br />

Occasionally sand deposits inside the sump becomes too much so that pumping has to stop<br />

for cleaning purposes.<br />

4.1.1.1.4 Suction side losses<br />

During the evaluation of the pump station, attention was also given to the length of the<br />

suction pipe and fittings that were used. Friction losses for pipes were calculated as for any<br />

other pipe (using Hazen-Williams equation) and secondary losses for fittings were calculated<br />

with the aid of the following formula:<br />

h<br />

f<br />

<br />

6375kQ<br />

4<br />

d<br />

2<br />

………………………………….. (4)<br />

Where: hf = secondary friction loss in fitting (m)<br />

k = friction loss factor (annexure 1)<br />

Q = flow rate in the fitting (m³/h)<br />

d = inner diameter of the fitting (mm).<br />

A summation of friction loss across the foot valve, the suction pipe, and the<br />

eccentric/concentric reducers gave a total hf of 0.6 meters when both pumps are running.<br />

Friction in the suction pipe had a direct effect of maximum suction height and consequently<br />

the available net positive suction head (NPSH) and is discussed below.<br />

4.1.1.1.5 Suction height<br />

The essence of this evaluation was to determine the actual static suction head of the installed<br />

pumps and then compare it to the designers suction height assumption. The maximum<br />

suction height was calculated using equation 5 below;<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 19 -


h<br />

s(max)<br />

hd<br />

hf<br />

hvp<br />

NPSH<br />

required ………………. (5)<br />

Where: hs (max) = maximum suction height (m)<br />

hd = atmospheric pressure on terrain (m)<br />

hf = suction side losses (friction losses, as well as secondary losses in fittings, m<br />

hvp = vapour pressure of water (m)<br />

NPSH required = net positive suction head from the pump curve (m).<br />

Figure 12. Atmospheric pressure vs. height above sea level<br />

The suction height was measured to be approximately 3 meters. The NPSH required of the<br />

100-50/2 (from a pump curve) is 1.6m and is 1m for the 125-50/2 pump. From the above<br />

formula the maximum allowable suction height is 7.2m and 8.32m for the two pumps<br />

respectively. This calculation confirms that river pumps were installed at the correct height<br />

above sea level.<br />

Further analysis compared NPSH available to NPSH required. NPSH requirements of 1.6 and<br />

1 meter are well within the available NPSH of 6.32 meters. A safety factor of 0.5 is not<br />

factored in this calculation as per manufacture’s requirement.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 20 -


4.1.1.2 Pump evaluation<br />

Table 1 below indicates <strong>Mavela</strong> irrigation pump specifications as observed from the<br />

information plate and tender document.<br />

Table 1. Pump and motor specifications and measurements conducted on all pumps<br />

PUMP SPECIFICATIONS FROM INFORMATION PLATE AND MEASUREMENTS<br />

Model KSB ETA 125 – 50/2 KSB ETA 100 – 50/2<br />

Number of units 1 1<br />

Estimated design duty point 198.7m³/h @ 66m 48.3m³/hr @ 66m<br />

Pump efficiency, % 78% 53%<br />

Impellor diameter mm 360 370/300 mm<br />

MOTOR SPECIFICATIONS FROM INFORMATION PLATE AND MEASUREMENTS<br />

Motor size, kW 55 30<br />

Revolution speed rpm <strong>147</strong>5 1465<br />

Motor efficiency, % 93.6 92.9<br />

Power factor, cos Q 0.87 0.89<br />

Current (measured) V 380 380<br />

Voltage (measured) A 90 53<br />

4.1.1.2.1 Power required on the pump shaft<br />

The power required on the pump shaft was calculated as soon as the total pump head and<br />

delivery was measured. The pump efficiency was obtained from the pump curve.<br />

Power required on the pump shaft was calculated with the following formula and establishes<br />

whether motors were sized accurately.<br />

P <br />

g H Q<br />

36,000<br />

………………………………………. (6)<br />

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Where: P = power required on the pump shaft (kW)<br />

ρ = density of water (1000 kg/m³)<br />

g = gravity acceleration (9.81 m²/s)<br />

H = pump pressure at service point (m)<br />

Q = pump delivery at service point (m³/h)<br />

η = pump efficiency at service point (%).<br />

With an operational duty points and pump efficiency shown in table 1 above, the required<br />

power on the pump shaft is a theoretical value of 45.8 kW and 16.4kW for the two pumps<br />

respectively. According the ARC, <strong>2007</strong>, the power output of the motor must be 10-15%<br />

greater than the power required on the pump shaft and corresponds respectively to 52.7 and<br />

18.8kW. Under this consideration, the 55kW motor is correctly sized and 30kW motor was<br />

over-sized.<br />

This required power is calculated based on the assumption that the 125-50/2 pump was<br />

designed for phase 1 (50.2ha) and the 100-50/2 for phase two (12.2ha). If total system<br />

capacity requirements (247m³/hr) are divided equally between these two pumps (123.5m³/hr)<br />

their duty points change to 123.5m³/hr@73m and 69% efficiency for pump no.1 and<br />

123.5m³/hr@52m and 68% efficiency for pump no. 2. The power requirement will, change to<br />

40.9kW and 29.6kW respectively, inclusive of 15% safety for motor selection. Under this<br />

consideration the 55kW motor is over-specified and the 30kW is of the acceptable size.<br />

A conclusion was therefore drawn that in view of the above scenarios the total kW required in<br />

this project is about 71kW and the two motors generate a total of 85kW. This is not<br />

acceptable, especially from a financial point of view as it, unnecessarily, escalates electricity<br />

costs.<br />

4.1.1.2.2 Pump Operation<br />

Pump curves of all the pumps were to be used to evaluate whether these pumps function as<br />

indicated by the pump curve. Measurements of the operating pressure and discharge from<br />

these pumps were to be used to determine the required power by these pumps. But because<br />

no flow meters were installed in this project this exercise could not be carried out.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 22 -


The require power<br />

P<br />

required of all the pumps was then compared with the output power (Pu) of<br />

the electric motor obtained from measurements of voltage and current. The output power of<br />

the motor was calculated using equation 7 below<br />

3IV cos<br />

P u<br />

<br />

……………………………………….. (7)<br />

1000<br />

Where: Pu = output power of the motor (input power of the pump) (kW)<br />

I = average measured current (A)<br />

V = average measured voltage (V)<br />

η = motor efficiency (fraction)<br />

cos ø = power factor (factor).<br />

The output power of both motors is indicated in table 2 below,<br />

Table 2. River pumps evaluation<br />

KSB ETA 125 – 50/2 KSB ETA 100 – 50/2<br />

P motor (information plate) kW 55 30<br />

P required kW 52.7 / 40.9 18.8 / 29.6<br />

Pu (motor output power) kW 48.2 28.8<br />

Classification Acceptable Over-sized<br />

In view of the fact that the 125-50/2 pump was designed for phase 1 correctly, the 100-50/2<br />

motor is therefore over sized. According to the ARC the configuration of the different power<br />

units must conform to the expression Pu = P < Pmotor. A smaller motor could have been<br />

used in this development.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 23 -


4.1.1.2.3 Pump Station General Evaluation<br />

‣ The pump house is cramped with very little working space.<br />

Figure 13. Inside <strong>Mavela</strong> pump station<br />

‣ The entire floor of this pump house and the access ladder is slippery. This is caused by oil<br />

that is spilt during pump maintenance. Walking here has become a safety hazard.<br />

‣ The access ladder to this pump house is too steep and is not properly anchored.<br />

‣ The drainage pump is not working and water is removed from the pump house using<br />

buckets. The floor was initially draining to a small sump inside the pump house in which a<br />

small electric drainage pump was installed. This used to pump the drainage water out of<br />

the pump house via a network of pipes.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 24 -


Figure 14. Malfunctioning drainage pump<br />

‣ During heavy rains or when a sprinkler is run close to the pump house water seeps into<br />

the pump house from the floor.<br />

‣ Pumps and motors do not have any safety mechanism, i.e. no flow switches etc<br />

Pump Alignment<br />

The alignment of the pump and the motor was also evaluated. This was done by placing the<br />

edge of a straight steel ruler over the coupling flanges at four points, 90º apart. This straight<br />

edge rested equally on all points on the flanges to ensure parallel alignment. The distance<br />

between the coupling levels at 90º intervals was also measured. A Vernier calliper was used.<br />

Measurements were the same on all the points, and on all pumps and that meant the unit<br />

was squarely aligned.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 25 -


4.1.2 P o w e r S u p p l y a n d C o n s u m p t i o n<br />

Power consumption<br />

A basic economic analysis was undertaken to ascertain the trade-off between capital and<br />

energy costs. For this economic analysis the Equivalent Annual Cost method (EAC) was<br />

used. The EAC adjusts the costs of items to a stream of equal amounts of payment over<br />

specified periods (equivalent annual costs) in order to enable comparison.<br />

Items costed were:<br />

‣ Infield irrigation (tape and fittings including flusher lines and valves - considered as<br />

polythene). Including installation costs.<br />

‣ Distribution system - pipelines (main lines and submains - considered as PVC).<br />

Including installation costs.<br />

‣ Pumping plant (including pump control valves, flow meters, electrical components,<br />

motors etc). Included installation costs. Where no new pumps were included, all and<br />

any supplementary equipment/operations connected with pumping e.g. upgrades,<br />

new impellors, new switchgear, new valves were included<br />

‣ Primary filter station (only filters and associated pipe work, valves etc).<br />

Excluded were:<br />

‣ All existing infrastructure (e.g. AC pipe, balancing dam, MCC housing, etc)<br />

‣ Buildings (e.g. cluster houses, pump stations, filter station structure)<br />

‣ Valves external to pump stations and filter stations.<br />

‣ Irrigation controller systems<br />

‣ Fertigation systems<br />

The operational costs for the schemes were confined to energy costs and maintenance<br />

(excluded labour. Admin etc).<br />

Interest rate: 10%<br />

Useful life (this analysis)<br />

Infield irrigation (Tape etc):<br />

10 years<br />

PVC/Poly pipe:<br />

Filters:<br />

Pumping equipment and electrics<br />

20 years<br />

15 years<br />

15 years<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 26 -


Maintenance<br />

Infield irrigation: 3%<br />

Distribution - pipelines: 2%<br />

Pumping plant: 1%<br />

Filters: 3%<br />

Capital Recovery Rate (CRF)<br />

factors:<br />

Volume water applied per hectare:<br />

SEB tariff – Consumption:<br />

Maximum demand:<br />

Efficiency of pumping plant<br />

(See attached table)<br />

14000m3/ha/annum<br />

0.22 E/kWh<br />

69.42 E/kVa<br />

Calculate at design duty point<br />

For sprinkler irrigation a 40% EAC value is accepted. A higher and a lower figure indicates<br />

over design and under design respectively<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 27 -


ITEM COST ITEM Main Bid<br />

1 Infield irrigation<br />

Capital cost (E)<br />

Useful life (years) 10<br />

Annual maintenance (%) 3<br />

EAC of infield irrigation (E)<br />

2 Distribution system<br />

Capital cost (E)<br />

Useful life (years) 20<br />

Annual maintenance (%) 2<br />

EAC of Distribution system (E)<br />

3 Pumping plant<br />

Capital cost (E)<br />

Useful life (years) 15<br />

Annual maintenance (%) 1<br />

EAC of Pumping plant (E)<br />

4 Filters<br />

Capital cost (E) -<br />

Useful life (years) 15<br />

Annual maintenance (%) 3<br />

EAC of Filters (E) -<br />

5 Annual Energy Cost (E) 78,825.46<br />

Total EAC (E)<br />

Energy cost as a % of total EAC<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 28 -


4.1.3 S u p p l y S y s t e m<br />

The evaluation of the supply system is discussed under the following headings:<br />

4.1.3.1 Mainline size<br />

SABI norm suggests that for raising main lines with a diameter of 200mm or smaller a<br />

maximum of 1.5m friction fore ach 100 m pipe length (1.5%) is allowed (ARC, 2003).<br />

Mainlines with pipe sizes greater than 200mm are evaluated by determining the most<br />

economical pipe diameter; capital and annual cost for different pipe diameters were<br />

compared and the following equation is used;<br />

d<br />

kQ<br />

0.37<br />

i<br />

…..……………………….……… (8)<br />

Where: di = inside diameter of pipe, mm<br />

K= constant derived from annual irrigation hours<br />

Q= flow rate (m 3 /h)<br />

<strong>No</strong> information was available on mainline pipe sizes, lengths and class and because there<br />

are no pressure measuring points on hydrants, friction loss through the mainline could not be<br />

calculated. So an undisputed conclusion on whether the supply system was correctly<br />

designed or not cannot be drawn until details on pipe size, pipe classes, and distances<br />

occupied by the different sizes are obtained.<br />

For annual irrigation hours of 3300, adopted by the sugar industry, the most economical pipe<br />

size diameter from the pump station was calculated for 247 m³/hr maximum design flow to be<br />

217.3mm inside diameter. This corresponds to a 250mm nominal pipe size. The actual size<br />

installed could not be ascertained but a pipe size smaller would mean the system is underdesigned<br />

and vice versa. The total mainline length is approximately 1600m and based on the<br />

above norm friction head losses should not exceed 25m.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 29 -


4.1.3.2 Mainline class<br />

For the same reason as above, this evaluation could not identify whether the mainline classes<br />

were over specified or not. Pipe bursts are one major indicator of under specification in pipe<br />

classes and none were experienced in the mainlines. Recurrent pipe burst were observed<br />

only on T-off takes to sub mains. This could be caused by either water hammer or airlocks in<br />

the system.<br />

4.1.4 S y s t e m c a p a c i t y e v a l u a t i o n<br />

The required total head of pumps was calculated by summing the following;<br />

Friction loss in the mainline (25)<br />

The sprinkler operating head (35) + riser height (3m)<br />

The pump suction head (3m)<br />

Secondary head losses<br />

Elevation change from pump house to critical sprinkler (5m)<br />

The two pumps in this pump station irrigated a total of 62.4 ha and system capacity is<br />

therefore calculated to be 247m3/hr inclusive of 10% safety for pump discharge. The<br />

summation of the above components reflects that each pump must generate at least 71m.<br />

Assuming a motor efficiency at least 70% the required power for this project is 68.3kW, which<br />

is a 75kW motor. The total motor size was evaluated to be 85kW. This section is, therefore,<br />

over-designed.<br />

The 125-50/2 pump equipped with a 398mm impellor and coupled to a 75kW motor can meet<br />

the entire projects irrigation and pressure requirements. The current installation requires two<br />

pumps to be operated in order to meet irrigation and pressure requirements. Upon rectifying<br />

this design error the second pump will not be required, except for back-up purposes and<br />

power will be reduced by 10kW.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 30 -


5 F I E L D E V A L U A T I O N O F S P R I N K L E R I R R I G A T I O N<br />

S Y S T E M<br />

Block Area (ha) 62.4<br />

Type of sprinkler system<br />

Dragline<br />

Name of Designer<br />

G4 Farm and Estate Development<br />

Name of contractor<br />

G4 Farm and Estate Development<br />

Design<br />

Measured<br />

Hydrant pressure (m) Na <strong>No</strong> pressure measuring point<br />

Sprinkler spacing (m x m) 18 18<br />

Lateral spacing (m) 72 54<br />

Stand pipe height (m) 3 3<br />

Pressure regulator <strong>No</strong> <strong>No</strong><br />

Dragline diameter (mm) 20 20<br />

Dragline length (m) Varies 20<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 31 -


5 . 1 P r e s s u r e r e a d i n g s<br />

The following pressure readings were taken:<br />

5.1.1 P r e s s u r e a t h y d r a n t<br />

Hydrant valves were installed on every lateral and were equipped with mechanical valves.<br />

Pressure at the hydrant could not be measured due to malfunctioning pressure measuring<br />

point. Instead pressure was measured on the first hydromatic from the hydrant valve<br />

assembly. This was measured with a hand made pressure measuring apparatus, where by a<br />

pressure gauge, was connected to a hydromatic and pipelet, was used. Hydromatics on the<br />

delivery side of the hydrant were used as pressure measuring points.<br />

Figure 15. Lateral hydrant valve<br />

All mechanical hydrant valves must be replaced with hydraulic valves, i.e. Bermad valve with<br />

a pressure-regulating pilot to accommodate the variation in block required pressure. The<br />

installation of this unit would reduce a higher inlet pressure to a lower constant outlet<br />

pressure, regardless of fluctuating flow rates and or varying inlet pressure. The pilot would<br />

sense down-stream pressure and modulates open or close, causing the main valve to<br />

throttle, thus maintaining constant delivery pressure.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 32 -


When down–stream pressure falls below the pilot setting, the pilot and main valve would<br />

modulate open to increase pressure and maintain pilot setting. When downstream pressure<br />

rises above the pilot setting, the pilot and main valve would throttle close to decrease<br />

pressure and maintains pilot setting. The pilot has an adjusting screw to preset the desired<br />

pressure.<br />

5.1.2 S p r i n k l e r p r e s s u r e<br />

The optimal operating pressure (kPa) of the sprinkler should be between 60 and 70 times the<br />

nozzle diameter (mm). This is applicable to nozzles of 3 to 7 mm diameter (ARC, 2006).<br />

Table 3. Optimal Operating Pressure Vs <strong>No</strong>zzle Diameter for Sprinklers<br />

<strong>No</strong>zzle diameter<br />

Operating pressure (kPa)<br />

Mm inches x 60 x 70<br />

1,59<br />

1 / 16 "<br />

1,98<br />

5 / 64 "<br />

2,38<br />

3 / 32 "<br />

2,78<br />

7 / 64 "<br />

3,18<br />

1 / 8 " 191 222<br />

3,57<br />

9 / 64 " 214 250<br />

3,97<br />

5 / 32 " 238 278<br />

4,37<br />

11 / 64 " 262 306<br />

4,76<br />

3 / 16 " 286 333<br />

5,16<br />

13 / 64 " 310 361<br />

5,56<br />

15 / 64 " 333 389<br />

5,95<br />

15 / 64 " 357 427<br />

6,35<br />

1 / 4 " 381 445<br />

Pressure at sprinklers was measured with a pressure gauge, fitted with a pitot tube (Figure<br />

16). The point of the pitot tube was held about 2 mm in front of the nozzle opening in the path<br />

of the jet of water to measure the “vena contracta”. Therefore, the velocity pressure, which<br />

indicates the pressure head and is equivalent to the total pressure, was measured.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 33 -


Figure 16. Pressure measurement with a pitot tube end pressure gauge<br />

The standpipes were three metres high and the pressure of the sprinklers was measured at a<br />

height of one metre above the ground, then 2 m (or 20 kPa) was subtracted from the<br />

pressure registered on the pressure gauge, in order to determine the sprinkler pressure at<br />

normal operating height.<br />

The choice of the sprinklers at which measurements were to be taken, was influenced by the<br />

different pressure zones in a specific irrigation block. In view of the undulating terrain (many<br />

height differences) in this project the total system was in operation as for normal irrigation<br />

before the evaluation. According to the ARC (2006) the number of measuring points must be<br />

representative of the block and the choice depended on the topography of the block, as well<br />

as the distance from the pump station. As per these recommendations complete<br />

measurements were taken at distances 0, L/4, L/2, 3L/4 and L on the lateral and at the same<br />

distance on the sprinkler lines (Figure 17).<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 34 -


0 L/4 L/2 3L/4 L<br />

L<br />

3L/4<br />

L<br />

L/2<br />

Test block<br />

L/4<br />

Test emitter<br />

0<br />

Hydrant<br />

Figure 17. Positions of complete sprinkler pressure measures in an irrigation block<br />

Pressure variation was calculated using equation 9 below and a summary of the results is<br />

outlined in table 8.<br />

Pmax<br />

P<br />

P <br />

P<br />

ave<br />

min<br />

………………………………………….. (9)<br />

According to the SABI norms, pressures in the block may not vary more than 20% of the<br />

average pressure. Pressure measurement results as indicated by the table below reflect an<br />

unacceptable pressure variation of 86.9%. The lowest pressure measurements were<br />

recorded from block 1, the first block from the pump house. When these are excluded<br />

pressure variation reduces to 32%, which is also unacceptable. The reason block 1 recorded<br />

the least pressure could not be confirmed but was attributed to the incorrect sub main and/or<br />

lateral design, leakages, and hydrant valve malfunctioning.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 35 -


Table 4. Pressure and nozzle size measurements results<br />

Measuring point Type of sprinkler/nozzle Measured<br />

nozzle<br />

diameter<br />

Measured<br />

nozzle pressure<br />

Block 1 Rain bird 14070 11/64" nozzle 4.5 165<br />

Block 1 Rain bird 14070 11/64" nozzle 4.5 200<br />

Block 1 Rain bird 14070 11/64" nozzle 4.37 280<br />

Block 2 VYRSA 70 11/64'' nozzle 4.37 480<br />

Block 4 Rain bird 14070 11/64" nozzle 4.5 400<br />

Block 4 Rain bird 14070 3/16" nozzle 4.76 430<br />

Block 4 RC 130 11/64'' nozzle 4.37 440<br />

Block 6 Rain bird 14070 11/64" nozzle 4.5 340<br />

Block 7 Rain bird 14070 11/64" nozzle 4.37 470<br />

Block 8 Rain bird 14070 11/64" nozzle 4.4 420<br />

Averages 4.412 4.464 362.5<br />

The installed pumps can meet the pressure requirements of this scheme; the operating<br />

average pressure of the system is above the recommended sprinkler operating pressure. The<br />

high system operating pressure and the unacceptable pressure variation was attributed to:<br />

Hydraulic Valves<br />

In essence hydraulic valves maintain the design lateral/block pressure ensuring uniform<br />

pressure thoughout the system. This irrigation system was installed in such a way that all<br />

laterals have individual isolation valves. Mechanical valves, instead of hydraulic valves are<br />

used in this installation hence the unacceptable variation in pressure. Sprinkler pressure<br />

ranges from 165kPa – 480kPa, with the installation of hydraulic valve sprinkler pressure will<br />

be maintained at the recommended sprinkler operating pressure of 350kPa in all blocks.<br />

Sprinkler pressure regulators<br />

Sprinkler pressure regulators were not installed. 350kPa sprinkler pressure regulators are<br />

required because these ensure that all nozzles operate at a maximum pressure of 350kPa,<br />

which is the recommended sprinkler operating pressure. Most blocks are fairly flat, when<br />

considering the quantity of the pressure regulators, this fact must be kept in mind.<br />

<strong>No</strong>zzle wearing<br />

The amount of sprinkler nozzle wear (mm) is on average 2.2% in all phases. An increase of<br />

5% in nozzle area means a 10% increase in flow and power demand, which means additional<br />

operating costs and over-irrigation. The ARC therefore recommends sprinkler replacement if<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 36 -


wear is greater than 5%. This irrigation system has been operated for almost 10 years but<br />

nozzle wearing is still low. The amount of sand particles sucked by booster pumps and pass<br />

through the nozzles is minimised as most of the sand carried from the river is deposited in the<br />

reservoir. Scour valves for facilitate cleaning of the pipe work are well installed in all submains.<br />

Sprinkler nozzles were measured after the system was switched off with a specially machined<br />

apparatus (Figure 18)<br />

Figure 18. Measuring apparatus for sprinkler nozzle size<br />

Number of sprinklers operated concurrently per lateral<br />

The lateral design is based on the number of sprinklers operating simultaneously on that<br />

lateral. Generally, the greater the number of sprinklers operating simultaneously, the bigger is<br />

the size of that lateral. When the farmers are irrigating they tend to connect sprinklers on all<br />

available hydromatics in that lateral and this severely increases friction loss within that lateral<br />

and mainline section thus reducing sprinkler pressure. The exact number of sprinklers per<br />

lateral must be indicated in the operation and maintenance manual.<br />

Leaks<br />

There are a lot of leaks in the system and this drastically reduces pressure. These leaks are<br />

observed mainly in sprinklers, sprinkler stand-dragline connections, broken dragline, pipelets,<br />

hydromatics, mainline, etc.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 37 -


Old Age<br />

The irrigation system was installed in 1998 and 200, over 10 years ago and as years elapsed,<br />

system efficiency reduces due to equipment wearing out. As a matter of urgency some<br />

equipment must be replaced and the rest maintained for optimal performance. Apart from<br />

nozzles, sprinklers, due to old age, are underperforming. Some draglines have more than the<br />

allowed tolerance of three joints and hydrant valves are faulty. These and other equipment<br />

has to be replaced.<br />

5 . 2 D e l i v e r y t e s t s<br />

The following delivery tests were conducted:<br />

5.2.1 S p r i n k l e r d i s c h a r g e<br />

According to the ARC the difference in discharge in a specific irrigation block may not vary by<br />

more than 10% from the average discharge, hence this evaluation. The discharge of the<br />

sprinklers was tested by collecting water into a container of known volume with a hose pipe<br />

connected to the sprinkler nozzle. A minimum container size of 20 litres is recommended and<br />

together with a stopwatch the time it took to fill the container was recorded. The open end of<br />

the hose pipe was not held under water in the container, but also not so high that the water<br />

splashed out of the container.<br />

Measurements were again taken at distances 0, L/4, L/2, 3L/4 and L on the lateral and the<br />

sprinkler line. The same points where pressure measurements were done were used and by<br />

taking the time it took to fill the container, the discharge was calculated with the following<br />

formula and results are shown in table 4.<br />

q<br />

e<br />

=<br />

average volume water measured incontainer<br />

average duration to fill container (sec)<br />

(litres)<br />

<br />

3600<br />

1000<br />

…………… (10)<br />

<br />

m<br />

3<br />

/hour<br />

Where q e = sprinkler discharge [m 3 /h]<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 38 -


Table 5. Discharge variation calculated from field measurements<br />

Type of sprinkler/nozzle size<br />

Measured nozzle discharge (m3/hr)<br />

Rain bird 14070 11/64" nozzle 1.00<br />

Rain bird 14070 11/64" nozzle 1.17<br />

Rain bird 14070 11/64" nozzle 1.20<br />

VYRSA 70 11/64'' nozzle 1.45<br />

Rain bird 14070 11/64" nozzle 1.73<br />

Rain bird 14070 3/16" nozzle 1.57<br />

RC 130 11/64'' nozzle 1.19<br />

Rain bird 14070 11/64" nozzle 1.21<br />

Rain bird 14070 11/64" nozzle 1.38<br />

Rain bird 14070 11/64" nozzle 1.30<br />

Minimum Discharge (m 3 /hr) 1.00<br />

Maximum Discharge (m 3 /hr) 1.73<br />

Average Discharge (m 3 /hr) 1.32<br />

Flow variation (%) 55.18<br />

Flow variation in this irrigation development was above the recommended maximum of 10%<br />

averaging a high of 55.18%. The average sprinkler application was found to be 1.32m³/hr<br />

instead of 1.4m³/hr stipulated in the <strong>Swaziland</strong> sugar industry standards. Again, when block 1<br />

sprinklers are eliminated the average sprinkler application improves to 1.38m³/hr. Sprinkler<br />

operating pressure and sprinkler discharge is directly proportional. When pressure<br />

decreases, sprinkler nozzle discharge also decreases and vice versa. This therefore, means<br />

all factors contributing to the low system pressure also contribute to the sprinkler nozzle<br />

discharge. The sprinklers that recorded a high operating pressure but low application rate had<br />

leaking draglines, tripods, and/or hydromatic-pipelet connection.<br />

The high nozzle/emitters variation observed in this project is one of the major reasons for the<br />

unacceptable flow variation. Different emitters respond differently to the same amount of<br />

pressure and table 6 below indicates the properties of the different sprinkler packages found<br />

on site.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 39 -


Table 6.Technical properties of sprinklers found on site at 35m operating pressure<br />

Sprinkler Package <strong>No</strong>zzle size Discharge (m3/hr Wetted Radius (m)<br />

VYRSA 70 11/64’’ 1.36 15.9<br />

Rain bird 14070 11/64’’ 1.39 14.8<br />

Rain bird 14070 3/16’’ 1.65 15.8<br />

RC 130 11/64’’ 1.36 15.9<br />

Three sprinkler packages with four different sprinkler–nozzle combinations were identified as<br />

shown in table 6 above. Flow variation due to the different sprinkler – nozzle combinations is<br />

20.14%, that is, emitter variation contributes more than 20% to the high flow variation<br />

observed in this project. This figure indicates that even on highly efficient pumping and supply<br />

system, irrigation efficiency will not improve, at least not until uniformity in this regard is<br />

obtained. The different combinations have an effect on the wetting diameter due to their<br />

different body trajectory angles. Farm management is using Somlo 46c plastic sprinklers with<br />

a 3/16’’ nozzle as replacement stock. In fact, since commissioning this development have<br />

fewer sprinklers than required. They are currently using 130 sprinklers instead of 161<br />

sprinklers.<br />

Gross application rate (GAR)<br />

The gross application rate (GAR) of the sprinkler was thereafter calculated, by means of the<br />

following formula;<br />

GAR <br />

qe<br />

1000<br />

A ....…………………………………. (11)<br />

mm/h<br />

Where; GAR = Gross Application Rate<br />

A = wetted area (m 2 )<br />

The recommended GAR according to industry norms is 4.33mm/hr and above calculation<br />

revealed an average of 4.1mm/hr and 4.2mm/hr without block 1 measurements. The GAR is<br />

a fraction of emitter discharge and sprinkler spacing. This low GAR is mainly caused by low<br />

sprinkler application rates.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 40 -


5 . 3 D i s t r i b u t i o n t e s t s<br />

This test could not be conducted because of the crop height (figure 19). The top of the rain<br />

gauge must not be more than 300mm above the ground surface or above the crop (ARC,<br />

<strong>2007</strong>). The test would be erroneous if carried out under these conditions because the<br />

vegetation would intercept the water distributed by the sprinklers and rain gauge readings<br />

would be incorrect.<br />

Figure 19. <strong>Mavela</strong> FA sugarcane above recommended testing height<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 41 -


6 A S S E S S M E N T O F O P E R A T I O N , M A N A G E M E N T<br />

A N D M A I N T E N A N C E O F T H E I R R I G A T I O N<br />

S Y S T E M<br />

6 . 1 O p e r a t i o n<br />

As-built drawings and design information not available<br />

The fact that no design or installation information is available consigns a huge constraint on<br />

management. Forward planning on aspects related to the irrigation infrastructure cannot be<br />

done, i.e. replacement stock purchase; item like pipes, fittings, etc are procured after<br />

breakages because the details of that particular pipe, fitting, etc is obtained from the broken<br />

part. This increases their down time and negatively impacts on crop production.<br />

Operation and maintenance manual not available<br />

The different components forming the irrigation system require different operating procedures<br />

and these are obtained from an operation and maintenance manual. This document, like all<br />

other documents, is not available and for efficient performance of these components, it must<br />

be compiled. The consequence of not having this document is seen during this evaluation in<br />

that incorrect sequences are followed in opening and closing the pump. Also, this document<br />

helps in the formulation of a maintenance plan and provides guidelines to be followed during<br />

maintenance.<br />

Financial viability for smallholder grower<br />

The late conclusion of loan agreements (seasonal loans) results in the late delivery of inputs<br />

and late application of fertilizers and chemicals, which reduces yields and sucrose content,<br />

resulting in reduced financial returns per hectare and inability to recoup invested capital. In<br />

addition, the absence of any dividends for distribution to farming association members at the<br />

end of each season can lead to a decline in the cohesion of farmers’ associations/cooperatives,<br />

a cohesion which is essential to increasing on-farm efficiency.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 42 -


Figure 20. <strong>Mavela</strong> weed infested sugarcane<br />

Interest Rates<br />

It can be argued that even relatively large reductions in interest rates have not had any<br />

significant impact on the sustainability of this sector. The sector appears to have deteriorated<br />

to one of a sustained financial crisis. This calls for an integrated programme of action, to look<br />

at:<br />

‣ Discounted tariffs with regards to bank charges, including administration fees.<br />

‣ A re-look at the repayment period with regard to capital loans, with a view to having it<br />

extended from the current 7 years to at least 10 years<br />

Considering the reduction of interest rates on all loans to a level not exceeding 12% per<br />

annum, such measures would allow smallholder growers to realize some return on their<br />

investment and to be able to eventually pay dividends to the investing members. Alternatively<br />

other financial arrangements can be put in place without any prejudice to the commercial<br />

operations of the financial institutions currently engaged with the sector (SSA, 2008).<br />

Electricity<br />

Energy costs are too high. During dry periods this FA shifts to a 24 hours day with three 8<br />

hour shifts. This means the pumps run continuously for 24 hours per day. There is a need to<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 43 -


have the tariffs looked at and, maybe have the tariff rate discounted for sugar cane growers<br />

to enable them to be sustainable in the business. It is imperative to train the farm manager<br />

and/or pump attendants on when and how many pumps to start at a time as this affects<br />

electricity maximum demand. Appendix three shows a calculation of the amount of energy<br />

used by this FA and compares it to what should have been used per season. This maximum<br />

demand calculation gives an indication of the amount small growers spend on electricity and<br />

how much could have been saved when pumps are operated correctly.<br />

Production Costs<br />

Sugar prices are on a continual downward spiral whereas production costs have taken the<br />

opposite direction, so that if no immediate plan of action is formulated to address the<br />

problem, most smallholder growers will slowly but surely perish. Fertilizers, herbicides, farm<br />

inputs, labour costs are making it difficult for the farmers to use the best farming practices.<br />

Maybe a solution to the problem could also be a consortium that can be formed for the<br />

sugarcane growing industry to have a muscle where buying of farm inputs is concerned<br />

(SSA, 2008).<br />

Transport costs<br />

Smallholder growers feel transporters have established a gold mine at the expense of<br />

growers. A large chunk of sugarcane revenue goes to the transporters and growers feel that<br />

there is a need to address this issue and look at ways to improve the current situation. The<br />

non performance of transport operators leads to a heavy loss in cane quality which also leads<br />

to a serious financial loss to the growers. The issue of mill distance from the farm is, in a<br />

number of instances, of major concern. The mere construction of a bridge (s) across a<br />

stream(s) would go a long way towards reducing these distances and, consequently, the<br />

attaching costs.<br />

Millers<br />

Smallholder cane growers feel that millers also have a significant role to play in assisting<br />

smallholder growers technically, financially and otherwise. Bulk purchasing comes to mind<br />

here as the millers are endowed with the financial muscle (economies of scale) which could<br />

result in discounted input prices for growers (SSA, 2008).<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 44 -


6 . 2 M a n a g e m e n t P r a c t i c e s<br />

Scheduling<br />

Effective scheduling ensures that the correct amount of water is applied at the right time and<br />

the correct place. As a scheduling method <strong>Mavela</strong> FA uses the give and take method. This<br />

method utilizes long term evaporation means and rainfall is accounted through rain gauge<br />

readings. An 8 hr stand time, and a 7 day cycle is adopted. Two shifts starting at 0600hrs –<br />

1400hrs – 1700hrs (finishing the next day) are implemented. The shortage of sprinklers<br />

complicates this exercise in that some blocks that have an irrigation cycle of more than 7<br />

days. During dry periods a 24 hour working day is implemented and this means sprinklers are<br />

moved at night, around 2200hrs.<br />

6 . 3 M a i n t e n a n c e S u r v e y<br />

When the impact of maintenance practices was evaluated, it was decided to classify the<br />

existing maintenance practices followed by the producer, according to existing literature<br />

sources as acceptable if it will not influence the performance of the system adversely and<br />

unacceptable/ineligible if it will impair the performance. The acceptable values are viewed as<br />

the absolute minimum values for the sustaining of an acceptable Us value in the system<br />

Table 7. Maintenance schedule for sprinkler irrigation systems<br />

Inspect the system for leakages<br />

Monitor With each cycle Annually<br />

Check system pressure and system flow<br />

<strong>Service</strong> air valves and hydrants<br />

Check sprinklers for wear and replace springs,<br />

washers and nozzles where necessary<br />

Flush mainlines<br />

X<br />

X<br />

X<br />

X<br />

X<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 45 -


Table 8. Maintenance practices implemented by <strong>Mavela</strong> FA<br />

Monitor Results Classification<br />

Inspect the system for leakages Attend to leaks only Unacceptable<br />

Check system pressure and system flow Never Unacceptable<br />

<strong>Service</strong> air valves and hydrants Never Unacceptable<br />

Check sprinklers for wear and replace springs,<br />

washers and nozzles where necessary<br />

Never<br />

Unacceptable<br />

Flush mainlines Annually Acceptable<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 46 -


7 C O N S T R A I N T S T O E F F I C I E N T S Y S T E M<br />

P E R F O R M A N C E<br />

PUMPS<br />

‣ The alignment of this sump in relation to the stream flow enables sand carried with the<br />

river water to be deposited inside the sump. In fact, when the Mbuluzi River is high<br />

<strong>Mavela</strong> loses irrigation time cleaning the sand out of the sump. This can take weeks.<br />

Also, during the dry season, due to river recession, sand bags are used to re-direct water<br />

from almost the centre of the river into the sump.<br />

‣ The suction pipe is not constructed to the correct dimensions in relation to the intake sump<br />

walls. The foot valve is installed too close to the bottom and the suction pipe is too close<br />

to the walls of the sump. These are not permanently anchored onto the sump and can be<br />

adjusted to meet the requirements.<br />

‣ The main suction manifold has a flow velocity of 1.46m/s, this is on the limits of the<br />

recommended velocity range and pump performance is negatively affected.<br />

‣ Incorrectly sized fittings in suction and delivery manifolds affect system performance. The<br />

effects of these are severe on the eccentric reducer because it is directly attached to the<br />

pump and the sudden restriction in size increases turbulence occurrences and cause<br />

irregular feeding of the pump hence cavitation. With such an installation wearing and<br />

maintenance cost of the pump will increase.<br />

‣ The power rating of both motors on site (85kW) is more than the expected 75kW. This is<br />

an indication of over-design hence more energy than required is used.<br />

‣ The pumps specified and installed in this project can supply much more than the required<br />

247m³/hr. The 125-50/2 pump equipped with a 398mm impellor and coupled to a 75kW<br />

motor can meet the entire projects irrigation and pressure requirements. The 100-50/2<br />

pump is not required, unless for backup purposes. Again, this is an indication of overdesign.<br />

‣ The absence of pressure and flow measuring devices in pump number 2 delivery manifold<br />

makes it impossible to measure and/or monitor pump performance.<br />

‣ The river pump house is characterised by poor floor drainage, steep access ladder,<br />

unavailability of working space, etc.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 47 -


MAIN LINE<br />

‣ An undisputed conclusion on whether the supply system was correctly designed or not<br />

cannot be drawn until details on pipe size, pipe classes, and distances occupied by the<br />

different sizes are obtained.<br />

‣ Pipe bursts are one major indicator of under specification in pipe classes and none were<br />

experienced in mainlines. Recurrent pipe burst were observed only on T-off takes to sub<br />

mains. This could be caused by either water hammer or airlocks in the system.<br />

‣ Some Air valves were leaking – overall system efficiency compromised<br />

SPRINKLER INFIELD IRRIGATION<br />

‣ On average irrigation blocks in this development received pressure above the<br />

recommended sprinkler operating pressure but the average sprinkler application rate is<br />

lower than required.<br />

‣ This dragline irrigation development has a design lateral spacing of 54m and 20m<br />

draglines. Site measurements revealed a lateral spacing of at most 55m and 25m<br />

draglines.<br />

‣ Sprinklers are not equipped with pressure regulators and were running on different<br />

pressures and deliveries.<br />

‣ Lateral hydrants are equipped with mechanical instead of hydraulic valves. Hydraulic<br />

valves maintain the recommended sprinkler operating pressure, throughout the block,<br />

ensuring uniform application throughout the system.<br />

‣ There is a huge variation in sprinkler packages and nozzle sizes. This variation means that<br />

even on highly efficient pumping, conveyance and distribution system irrigation efficiency<br />

will not improve, at least not until uniformity in this regard is obtained. The different<br />

sprinkler packages have an effect mainly on the wetting diameter due to the different<br />

body trajectory angles and the nozzle sizes have an effect on flow rate.<br />

‣ When the farmers are irrigating they tend to connect sprinklers on all available<br />

hydromatics in that lateral and this severely increases friction loss within that lateral and<br />

mainline section thus reducing sprinkler pressure.<br />

‣ There are a lot of leaks in the system and this drastically reduces pressure. These leaks<br />

are observed mainly in the sprinklers, sprinkler stands and dragline connections, and<br />

broken draglines.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 48 -


‣ The first phase of the irrigation system was installed over 10 years ago, and as years<br />

elapsed, the system efficiency reduces due to equipment wearing out. As a matter of<br />

urgency some equipment must be replaced and the rest maintained for optimal<br />

performance.<br />

‣ The distribution test could not be carried out because the sugarcane crop is almost<br />

reaching full canopy. There is no place for placing the gauges within the block without<br />

inference from the crop.<br />

‣ The whole irrigation development has no drainage and subsurface and surface drains are<br />

required.<br />

‣ Sprinkler nozzle wear is up to 2.2%<br />

‣ Pressure and flow measurement results as indicated an unacceptable pressure and flow<br />

variation of 86.9% and 55.18% respectively.<br />

OVERALL MANAGEMENT AND MAINTENANCE<br />

Operations<br />

‣ Financial viability for smallholder grower<br />

‣ High Interest Rates<br />

‣ Electricity cost high<br />

‣ High Transport costs<br />

‣ High Production Costs<br />

Management and maintenance<br />

‣ <strong>No</strong> scheduling measurements were followed<br />

‣ Areas that require drainage are difficult to manage<br />

‣ Without an operation and maintenance manual, management have difficulty in operating<br />

and maintaining the system. Incorrect operation procedures are followed and improper<br />

maintenance schedules adopted.<br />

‣ The fact that no design or installation information is available consigns a huge constraint<br />

on management. Forward planning on aspects related to the irrigation infrastructure<br />

cannot be done, i.e. replacement stock purchase; item like pipes, fittings, etc are procured<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 49 -


after breakages because the details of that particular pipe, fitting, etc is obtained from the<br />

broken part.<br />

‣ Old equipment reduces efficiency of system. This equipment includes hydromatics,<br />

draglines, tripod stands, sprinkler and nozzles. The most economic decision would be to<br />

replace this equipment instead of maintenance.<br />

‣ The different soil series on which the project is developed has different water holding<br />

properties and require different irrigation patterns. These are difficult to manage.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 50 -


8 R E C O M M E N D A T I O N S<br />

To evaluate the constraints of the project properly we have decided to categorised the<br />

recommendations in four categories namely<br />

A. Immediately: This has to been done direct after harvesting.<br />

B. Short term: This has to been done this season<br />

C. Medium term: This has to been done before replant<br />

D. Long term: This has to be rectified with replant.<br />

PUMPS<br />

Immediately:<br />

‣ Modify design of intake sump to minimise amount of sand carried with the river water and<br />

deposited inside the sump E 50 000.00<br />

‣ Upgrade 125-50/2 pump to run on full capacity e.g. install full size impellor and 75kW<br />

motor then disconnect the 100-50/2 pump E 80 000.00<br />

‣ Rehabilitate pump house, i.e. fix drainage pump, attend to seepage problem, etc<br />

E 10 000.00<br />

Medium term:<br />

‣ Reposition suction manifold on the sump ensuring that the required dimensions from the<br />

sump walls are met E 15 000.00<br />

‣ Replace all incorrectly dimensioned fittings on the suction and delivery manifold with the<br />

correct size E 5 000.00<br />

‣ Install flow meter, pressure gauges, pump and motor safety, etc E 50 000.00<br />

‣ Do routine maintenance on all equipment. E 5 000.00<br />

Long term:<br />

‣ Replace the suction pipe with a bigger size. E 35 000.00<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 51 -


MAIN DISTRIBUTION LINE<br />

Immediately:<br />

‣ Fix all leaking air valves and control valves. E 2 500.00<br />

‣ Identify pipe sizes, lengths, classes and orientation of mainline<br />

‣ Install additional air valves E 7 500.00<br />

Short term:<br />

‣ Do routine maintenance on all equipment. E 2 500.00<br />

SPRINKLER INFIELD IRRIGATION<br />

Immediately:<br />

‣ Install hydraulic valves in place of mechanical vales E 35 000.00<br />

‣ Install identical sprinklers with identical nozzle sizes and of the acceptable quantity<br />

(2.57sprinklers/ha) E 25 000.00<br />

‣ Fix all damaged sprinkler stands and replace leaking draglines and other malfunctioning<br />

equipment E 25 000.00<br />

Long term:<br />

‣ Replant the areas that perform badly.<br />

‣ Equip all sprinklers with pressure regulators ` E 20 000.00<br />

‣ Install proper sub-surface and open drainage where possible E 80 000.00<br />

‣ Abandon soils with a poor potential, and plant alternative crops<br />

OVERALL MANAGEMENT AND MAINTENANCE<br />

Operations<br />

‣ Considering the reduction or termination of interest rates on all loans, such measures<br />

would allow smallholder growers to realize some return on their investment and to be able<br />

to eventually pay dividends to the investing members. Alternatively other financial<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 52 -


arrangements can be put in place without any prejudice to the commercial operations of<br />

the financial institutions currently engaged with the sector.<br />

‣ There is a need to have the electricity tariffs looked at and, maybe have the tariff rate<br />

discounted for sugar cane growers to enable them to be sustainable in the business.<br />

Pump attendance must be trained on economic ways of operating pumps.<br />

‣ A consortium could be formed for the sugarcane growing industry to have a muscle where<br />

buying of farm inputs is concerned. This could reduce production costs<br />

Management<br />

‣ A proper scheduling tool must be adopted and, where possible, blocks scheduled<br />

according to soil type.<br />

‣ Compilation of an operation and maintenance manual to assist in the implementation of a<br />

proper maintenance strategy for the association.<br />

‣ Establish arrangement with a reliable establishment to assist with the maintenance of all<br />

equipment.<br />

‣ Replace all old equipment<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 53 -


9 C O N C L U S I O N<br />

This 62.6ha dragline irrigation development was designed and constructed by G4 Farm and<br />

Estate Development in two phases. The first phase of 50.2ha was constructed in 1998 and in<br />

2000 the second phase of 12.4 ha was completed. <strong>Mavela</strong> is an association of 15 members<br />

and is situated in Dvokolwako, supplied by Mbuluzi River.<br />

Pump Station<br />

An intake sump was constructed in 2002 after experiencing recurrent mechanical problems<br />

with their pumps. The alignment of this sump in relation to the stream flow enables sand<br />

carried with the river water to be deposited inside the sump. In fact, when the Mbuluzi River is<br />

high <strong>Mavela</strong> loses irrigation time cleaning the sand out of the sump. This can take weeks.<br />

Also, during the dry season, due to river recession, sand bags are used to re-direct water<br />

from almost the centre of the river into the sump. To eradicate this problem E 50 000.00 will<br />

be sufficient.<br />

The suction pipe is not constructed to the correct dimensions in relation to the intake sump<br />

walls. The foot valve is installed too close to the bottom and the suction pipe is too close to<br />

the walls of the sump. These are not permanently anchored onto the sump and can be<br />

adjusted to meet the requirements.<br />

The electricity cost of this scheme is magnified by the fact that the power rating of both<br />

motors on site (85kW) is more than the expected motor rating 75kW. The 10kW difference in<br />

energy is power not required and the farmers are paying for it. The pumps installed in this<br />

project are also over designed; they can supply much more than the required 247m³/hr. The<br />

125-50/2 pump equipped with a 398mm impellor and coupled to a 75kW motor can meet the<br />

entire projects irrigation requirements. The 100-50/2 pump is not required, unless for backup<br />

purposes. Various alternatives are available to solving this design error but E80 000.00 is<br />

sufficient to upgrade the 125-50/2.<br />

The incorrectly dimensioned eccentric reducer installed on the suction manifold of the pump<br />

could cause damage to the pump on the long term. To refurbish this and all other fittings will<br />

cost approximately E5 000.00<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 54 -


Main Distribution Line<br />

An undisputed conclusion on whether the supply system was correctly designed or not<br />

cannot be drawn until details on pipe size, pipe classes, and distances occupied by the<br />

different sizes are obtained. Pipe bursts are one major indicator of under specification in pipe<br />

classes and none were experienced in mainlines. Recurrent pipe burst were observed only<br />

on T-off takes to sub mains. This could be caused by either water hammer or airlocks in the<br />

system.<br />

Additional air valves must be installed and the mainline pipe sizes, lengths, classes and<br />

orientation be confirmed. This will cost just under E10 000.00<br />

Infield Sprinkler Irrigation<br />

All laterals are equipped with mechanical control valves instead of hydraulic valves. Sprinkler<br />

pressure measurements revealed an average operating pressure above the recommended<br />

sprinkler operating pressure. Pressure and flow variation is, however, above the<br />

recommended values at 86.9% and 55.18% respectively. This is caused, amongst others, by<br />

the wide variation in sprinkler packages and nozzle sizes. This variation means that even on<br />

highly efficient pumping, conveyance and distribution system irrigation efficiency will not<br />

improve, at least not until uniformity in this regard is obtained. The different sprinkler<br />

packages have an effect mainly on the wetting diameter due to the different body trajectory<br />

angles and the nozzle sizes have an effect on flow rate.<br />

Apart from this, <strong>Mavela</strong> irrigation scheme is characterised by no sprinkler pressure regulators,<br />

less than 2.57sprinklers/ha are operated simultaneously, nozzle wear of up to 2.2%, old and<br />

leaking equipment, etc. An immediate solution to these problems will cost E85 000.00 only.<br />

Management:<br />

The lack of design or installation information consigns a huge constraint on management.<br />

Forward planning on aspects related to the irrigation infrastructure cannot be done, i.e.<br />

replacement stock purchase; item like pipes, fittings, etc are procured after breakages<br />

because the details of that particular pipe, fitting, etc is obtained from the broken part.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 55 -


Irrigation scheduling is not practised and a proper irrigation scheduling tool will have to be<br />

introduced to the industry, especially for small holder farmers association. Various scheduling<br />

tools are widely used in the industry and these include tensiomentry, neutron probes etc.<br />

Performance of this irrigation scheme is affected, to some extend, by a lack or late application<br />

for fertilisers, herbicides, etc, high interest rates, high electricity cost, and the ever increasing<br />

production cost.<br />

Apart from these problems, operation, management and maintenance of this scheme is<br />

complicated by the lack of an operation and maintenance manual, insufficient pressure on<br />

some blocks, old and worn-out equipment, and frequent breakages of pumps, laterals and<br />

draglines.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 56 -


10 L I T E R A T U R E R E F E R E N C E S<br />

1. ARC- Institute for Agricultural Engineering,1998. In-field Evaluations of the<br />

Performance of two Types of Irrigation Emitters executed on behalf of the water<br />

Research Commission. Water Research Commission, Republic of South Africa.<br />

2. ASAE Standards. 1997. Field evaluation of micro-irrigation systems, ASAE EP458.<br />

3. ASAE Standards. 1998. Design and installation of micro-irrigation systems, ASAE EP<br />

405.1<br />

4. Burt, C.M. & Styles S.W. 1994. Drip and micro-irrigation for Trees, Vines, and Row<br />

Crops. Irrigation Training and Research Centre (ITRC). USA.<br />

5. Keller, J, and Bliesner, RD. 1990. Set Sprinkler Uniformity and Efficiency Sprinkle and<br />

Trickle Irrigation. Chapman and Hall, New York.<br />

6. Koegelenberg, F. H. & others. 1996. Irrigation Design Manual. Agricultural Research<br />

Council - Institute for Agricultural Engineering. RSA.<br />

7. Koegelenberg, F. H. 2002. <strong>No</strong>rms for the design of irrigation systems. Agricultural<br />

Research Council - Institute for Agricultural Engineering. RSA.<br />

8. Reinders, F.B. 1986. Evaluation of irrigation systems. Directorate of Agricultural<br />

Engineering and Water provision. RSA.<br />

9. Reinders, F.B. 1996. Irrigation Systems: Evaluation and Maintenance. SA Irrigation,<br />

Vol. 5-7.<br />

10. Scott, K. 1997. Designing with Sprinklers. Unpublished literature. ARC- institute For<br />

Agricultural Engineering. Silverton, Republic of South Africa.<br />

11. Scott, K. 1998. The effects of wind in sprinkler irrigation. ARC- Institute for Agricultural<br />

Engineering. Republic of South Africa.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 57 -


12. Solomon K.H. 1988a, Irrigation Systems and Water Application Efficiencies. Centre<br />

for Irrigation Technology, California State University, Fresno, California.<br />

13. Solomon K.H. 1988b.A new way to view Sprinkler pattern, Center for irrigation<br />

Technology, California State University, Fresno, California.<br />

14. Solomon, K.H. 1990. Sprinkler Irrigation Uniformity, center for irrigation Technology,<br />

California State University, Fresno,California.<br />

15. Solomon, KH Zoldoske, DF and Oliphant, JC. 1996. Laser Optical Measurement of<br />

Sprinkler Droplet Sizes. Center for irrigation Technology, California State University,<br />

Fresno, California.<br />

16. SSA.2001. Sugar Production Manual. <strong>Swaziland</strong> Sugar Association. Mbabane<br />

17. SSA.2008. www.ssa.co.sz<br />

18. Zoldoske, D.F. and Solomon, K.H. 1988. Coefficient of Uniformity- What it tells us.<br />

Center for irrigation Technology, California State University, Fresno, California.<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 58 -


11 P R O D U C T I N F O R M A T I O N<br />

River pumps technical details;<br />

Sprinkler equipment<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 59 -


<strong>Mavela</strong> Farmer Association Report - 2009 Page - 60 -


<strong>Mavela</strong> Farmer Association Report - 2009 Page - 61 -


Block hydrant valve specifications from the manufacture<br />

Soils classification according to SSA<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 62 -


<strong>Mavela</strong> Farmer Association Report - 2009 Page - 63 -


<strong>Mavela</strong> Farmer Association Report - 2009 Page - 64 -


12 A P P E N D I C E S<br />

Attached are the following documents<br />

Appendix 1: SEB usage for pumps<br />

Appendix 2: capital recovery factors (CRF)<br />

Appendix 3: soil map and block layout<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 65 -


CAPITAL RECOVERY FACTORS (CRF)<br />

Interest Rates<br />

Years<br />

% 2 3 4 5 6 7 8 9 10 15 20<br />

5 0.538 0.367 0.282 0.231 0.197 0.173 0.155 0.141 0.130 0.096 0.080<br />

6 0.545 0.374 0.289 0.237 0.203 0.179 0.161 0.<strong>147</strong> 0.136 0.103 0.087<br />

7 0.553 0.381 0.295 0.244 0.210 0.186 0.167 0.153 0.142 0.110 0.094<br />

8 0.561 0.388 0.302 0.250 0.216 0.192 0.174 0.160 0.149 0.117 0.102<br />

9 0.568 0.395 0.309 0.257 0.223 0.199 0.181 0.167 0.156 0.124 0.110<br />

10 0.576 0.402 0.315 0.264 0.230 0.205 0.187 0.174 0.163 0.131 0.117<br />

11 0.584 0.409 0.322 0.271 0.236 0.212 0.194 0.181 0.170 0.139 0.126<br />

12 0.592 0.416 0.329 0.277 0.243 0.219 0.201 0.188 0.177 0.<strong>147</strong> 0.134<br />

13 0.599 0.424 0.336 0.284 0.250 0.226 0.208 0.195 0.184 0.155 0.142<br />

14 0.607 0.431 0.343 0.291 0.257 0.233 0.216 0.202 0.192 0.163 0.151<br />

15 0.615 0.438 0.350 0.298 0.264 0.240 0.223 0.210 0.199 0.171 0.160<br />

<strong>Mavela</strong> Farmer Association Report - 2009 Page - 66 -

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