Service Contract No 2007 / 147-446 Mavela Farmers ... - Swaziland
Service Contract No 2007 / 147-446 Mavela Farmers ... - Swaziland
Service Contract No 2007 / 147-446 Mavela Farmers ... - Swaziland
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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 />
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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 />
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Block hydrant valve specifications from the manufacture<br />
Soils classification according to SSA<br />
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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 />
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