"Twin Line"

Do you have extra hose you leave at home?  Does a significant amount stay on your reel?  Are you wondering how to gain gallons per minute and distance?  Is an underground pipeline limiting your flow rates because of pressure restrictions?

Sometimes, a good solution can be splitting the outflow at your pump into two lines that lay side by side.  Maybe one of those lines jumps into an underground pipeline and it's sister line continues to run above ground.  Then, they meet at the center pivot and join into another pump.  Perhaps that pump is ready to push through the last few pieces of drags to the tractor, the process is repeated with another set of twin line, or they merge through a single hose for a shorter distance.  

The idea is to decrease friction losses by allowing each hose to flow half of our total flow rate.  

Let's say you have a pump unit at the manure storage site that will flow 1750 GPM.  Perhaps it's a PCE PT 2047 with a 4NHTB Cornell Pump and a 275 horsepower JD 6.8 L engine. This works with any pump, just be sure to consult your pump curve.

If we take a look at the pump curve, we can follow the CAPACITY across the bottom to 1750 GPM - that's our goal.  On the left vertical axis, find 2000 RPM at the top. Follow that dark black line over to where it meets 1750 gallons per minute (GPM).  This just over the 250 horsepower requirement, noted on the right side of the chart by the slashed line traveling diagonally up and to the left.  Along the top of the chart 20 FT is noted as NPSH REQUIRED.  The pump will require close to 21 FEET of head coming into the pump to operate correctly at this flow.

The chart shows with all these requirements filled, the pump will produce about 400 FEET of Total Dynamic Head (TDH).  400 divided by 2.31 equals 173 PSI.

If we split the 1750 gallon per minute outflow into 2 lines each flowing 875 gpm, lets see how far we can go compared to a single line flowing the full 1750 gpm.

Single 8 inch line @ 1750 = 23.5 feet of head loss per 660 ft. length
400/23.5 = 17 lengths of distance

Single 7 inch line @ 1750 = 45 feet of head loss per 660 ft. length
400/45 = 8.88 lengths of distance

Single 6 inch line @ 1750 = 95 feet of head loss per 660 ft. length
400/95 = 4.21 lengths of distance

Single 5 inch line @ 1750 = 232 feet of head loss per 660 ft. length
400/232 = 1.72 lengths of distance

(8 lengths per mile, or 200 meter lengths)


Twin 8 inch line @ 875 gpm each = 6.5 feet of head loss per length
400/6.5 = 61.5 lengths /2 = 30.7 lengths for each line
divided by 8 = 3.8 miles (compared to 2.125 miles solo with the same pump at the same flow rate)

Twin 7 inch line @ 875 gpm each = 12.5 feet of head loss per length
400/12.5 = 32 lengths /2 = 16 lengths for each line
divided by 8 = 2 miles (compared to 1.1 miles with a solo line at the same flow with the same pump)

Twin 6 inch line @ 875 gpm each = 26.5 feet of head loss per length
400/26.5 = 15 lengths /2 = 7.5 lengths for each line
divided by 8 = 0.94 miles (compared to 0.52 miles with a solo 6 inch hose)

Twin 5 inch line @ 875 gpm each = 64.3 feet of head loss per length
400/64.3 = 6 lengths /2 = 3 lengths for each line
divided by 8 = 0.375 miles

In conclusion, a twin line can help you maximize the ability of a single pump to reach it's best gallons and best distance.

These numbers are based on cool water.  They do not take into account elevation changes, requirements of the next pump in line, variations in temperature or changes in direction.  This is just a guideline to show how a single scenario would work in theory.

Please post questions and comments below or give us a call.  712-653-3045

Thank you!

Headed to the North American Manure Expo next week in Prairie du Sac, Wisconsin. 

On Tuesday, August 21st, Puck Custom Enterprises will present Pump School in Baraboo, WI.  Register Online! Class starts at 12:30, and will be followed with a digester tour at 3:30. For those interested, sign up:  http://www.surveymonkey.com/s/PWJKYDT  

At Pump School, Ben Puck and team will discuss how manure applicators can get the best performance out of their pumps by reviewing the fundamentals of how high pressure pumps work, how to read and understand pump curves, and how to calculate friction losses in lay-flat hose to better place inline units.  Increasing flow from 1200 GPM to 1500 GPM can mean a savings of over 100 hours for 40 million gallons.  That can equal quality savings in fuel and labor for an operation. 

The following day, Wednesday, August 22nd is the Expo.  PCE will have a live demo of the Agitation Boat.  Remotely controlled from shore, the agitation boat is a floating pump & engine unit using high pressure nozzles to shoot liquid downward and stir up solids on the bottom.  Mixing lagoons in this manner provides the best unified product to pump to the field and apply as nutrient. The agitation boat isn't limited by access points to the lagoon, and can be directed over trouble areas to bring piles of solids into suspension for pump out.

Also showcased in live demonstrations will be PCE's MobileStar™ Pump Control system.  MobileStar™ is a cellular-internet based technology to send and receive engine signals. From a computer or tablet, a user can turn the engine on or off, control and monitor engine RPM, open and close hydraulic gates on the trailer, prime the pump, and read inflow and outflow pump pressures.  These controls give the user an ability to fine-tune a system and manually synchronize pumps to optimize flow rates. 



For more information, please visit www.puckenterprises.com or visit with us at the show!

Green Corn

Pictures showing the effects of manure application and apparently boat stirring of lagoon. Had same application rate with very little variance.  Finished bottom 4 1/2 Acres following morning, that would be picture showing mid way down the run looks like I turned on a light switch. Apparently what was in hose from night before ran me to that point and then the new for the day was way different. Field I did a month later across the driveway from same lagoon looks basically the same way even though rate on it was around 15000 GPA and ones in these pictures was 25000 GPA. Jammie and ag guys have been looking at and kind of stumped by the huge difference in appearance. He said that after walking and looking at yesterday lighter colored corn is good and at the same leaf stage and such. This is highly productive ground. They did pull some soil tests to run and see what they show. Thought you might like these pictures as they show such a distinct difference. Would expect strips to look like that if they were non applied, but not as distinct as these when all was injected. Think I am headed out now to get equipment around to do a big 250,000 gallon nursery job.

Thanks

David Stephens

NPSHr

Net Positive Suction Head Required

All pumps have requirements to their performance, and no pump can perform well if you can't meet it's needs.

Below is part of the Cornell® 6NHTB-19 Pump Curve with a colored over-lay for this discussion.

NPSH REQUIRED is found at the top of the curves in FT.

What does this mean?

For this pump, running at 2100 RPM with its horsepower requirements met, you can pick a flow rate and easily find its NPSH REQUIRED.

1500 GPM = 5.5 FT.
2000 GPM = 8 FT.
2500 GPM = 11 FT.
3000 GPM = 17 FT.

Net Positive Suction Head Required is the required feet of head going into the back of the pump for it to function properly and achieve your desired flow rate.

Easy signs your pump's NPSHR is NOT met: 

• The pump is shaking
• It sounds like you have rocks going through your pump
• Gauges and Valves are falling off
• The unit is vibrating
• The tongue's jack is sunken into the ground from vibration
• Your gauges are broken
• Your suction cover shows physical damage of gouging and wash-out
• Your impeller shows physical damage of gouging and wash-out

CAUTION! Your Pump is Cavitating! 
More about cavitation: http://www.engineersedge.com/pumps/cavitation.htm



MEETING NPSH REQUIRED AT THE SITE:

Atmospheric Pressure – Friction Loss in Intake Hose – NPSHr of Pump = Static Suction Lift

• Static Suction Lift tells us the maximum distance from the top of the water to the center of the pump's impeller we can operate within without causing cavitation.  The pump needs to be primed, but not fed with another pump within this distance.
• Atmospheric Pressure is the force of air pressing down on a body of water - providing us with free FEET OF HEAD: we will use an easy-to-remember and conservative estimation of 30 FT. for atmospheric pressure.
• Friction Loss in Intake Hose is estimated using a C-140 Head Loss Chart.  See Below. We have modified it for 25 FT lengths. example: 10" Hose at 2000 GPM = 0.5 FT
  
  
• NPSHr is found on the pump's curve at a given flow rate. example: 2000 GPM = 8 FT.

30 FT. – 0.5 FT – 8 FT. = 21.5 FT

21.5 FT = the maximum distance from the top of the body of water to the center of the pump impeller that this pump can operate at without being force-fed and without cavitation at 2,000 GPM.  If you drop the flow rate, these numbers change and it has less NPSHr, and more Static Suction Lift

Call or write with Questions!

712-653-3045 - PCE Office

nancypuck@gmail.com - Nancy
bpuck@puckenterprises.com - Ben
jpuck@puckenterprises.com - Jeremy

Jake Pumps 3,000 gallons per minute

This is Jake. After high school he joined the military, fought overseas, and came home to Manning to raise his family. He can fly the United States flag as he'd like, and he certainly makes sure there is one on his tractor. POW on one side, Stars & Stripes on the other.

This fall he's quite consistently pumping over 2,500 gallons per minute. When I took these photos he was right over 3,000 - about 3020 GPM most of the time.

At a local finishing barn, his crew had a Lead Pump at the site, and a booster pump in the field. Both were set up with MobileStar. 

Lead Pump - a 550hp 13.5L John Deere with a 6NHTB-19 Cornell pump using a PCE Self-Prime system.  

Booster Pump - PT 5069 - same engine and pump as the lead.

Mainline Hose: 8 inch

Drag Hose: 6 inch

On the tractor he has a PCE Tractor-Mounted Swing Pipe with a PCE injection bar set up with Dietrich 70 Series Shanks to inject 5-6 inches deep.

This is a PCE text-book turn-around: making a "golf-club" swing, placing the bar back into the ground along the fence line, and slowly turning back to a 45 degree angle across the field. No backing up. 

Pretty....even when covered in Manure.

When it comes to friction loss in hose, it takes 7 lengths* of 8" hose to equal the friction loss in 2 lengths of 6" hose. That friction loss is equal to 0.85 lengths of 5 inch hose.

 *1 length = 660 ft.

***friction loss is still an estimation based on flow through materials similar to hose.

New lead pump

First day out with the new prototype lead pump.  John Deere 9.0 liter with a 6nhtb-19.  PCE fast prime and down riggers to level it out at the site.  Working great so far.

Agitation Boat - Front Cannon!

Last week, I was fortunate enough to travel north with Dad to South Dakota and Minnesota. We visited two pumping sites in South Dakota that were running PCE Agitation Boats on dairy lagoons.

The first dairy we visited was being pumped by Precision Pumping, Inc. of Minnesota.  They have an early model of BOAT 2067 with a Cornell Redi-Prime® Pump. We delivered a front nozzle attachment for the "cannon" - the Gate 3 outflow above water. This outflow can be used to sink solids floating on the top, to wash down the banks, or to deliver fluid through a hose (if the boat is anchored to shore).

Upon arrival at the lagoon, there was 12"-18" of crust on the top of the lagoon, with 2 lagoon pumps agitating - one at each end.

Lagoon Condition BEFORE Boat Agitation

 Over a very short period of time using the front nozzle, the Agitation Boat broke through the thick crust in the center and traveled to the opposite end, where Dad shut down the rear agitation nozzles against the bank, and used the front nozzle under the water to rotate the boat left and right while running the front cannon above the water.  This unit moves about 4,000+ GPM.

Using the Agitation Boat as stationary agitation against a bank

See another video of this at: http://www.malechainc.com/blog.html


With the control to individually open & shut 3 different outflow gates, you have a lot of control over agitation. The gates can be utilized to control the amount of flow through each agitation nozzle by only partially opening or closing a gate. Throughout the video, you can see variations in flow out the front cannon as the other gates are opened or closed.