Electric Irrigation Pumps - Performance

and Efficiency
January 2015 Primefact 1410
DPI Agriculture Water Unit

Tests of irrigation pumps across New South Electronic meters

Wales have found that many were not performing Electronic meters usually measure and record
efficiently, either because the wrong pump had the electricity used for the main rate, shoulder
been chosen for the job, or because the pump rate and the off-peak rate in separate registers.
was worn. The various rates are switched ‘on’ and ‘off’ by
If the pump is not doing its job, this can increase the internal clock at the appropriate times.
pumping costs and reduce productivity. To Electronic meters record your electricity
contain costs, you need to monitor your energy consumption in a time-of-use format. They may
usage regularly and repair and maintain the also have registers for the date, the time and for
pump to operate efficiently. testing the display.
This Primefact describes a simple way to work Electronic Power Meter
out the pumping costs and the energy efficiency
of your electric pump.
When you have determined the operating cost
you can perform quick checks to detect any
change, and when you have determined the
pump efficiency, you can compare it to the
manufacturer’s figures to decide when repair or
replacement is cost-effective.

Measuring operating costs

One way of tracking pumping costs is to work out
how much it costs to pump a megalitre of water.
To do this, you need to measure:
1. the power consumption rate in kilowatts (kW)
2. the flow rate in litres per second (L/s). Each register has a 3-figure identification
number. For example, the current off-peak
Combining these measures with the cost of kilowatts may be given register number ‘126’.
electricity gives the pumping cost. You should check with your local energy authority
(Worksheets with the following steps are what the display register numbers are for each of
provided at the end of this Primefact for your your rates.
use.) The meter scrolls through each register at 4–6
second intervals.
Step 1: Measure the power used
You can measure the power used by reading • The register number appears, often in smaller
your electricity meter. Electronic meters are most numbers, on the LCD screen (in the diagram,
commonly used but single and multiple meters in the top left-hand corner) and may have a
continue to be used on many farms.
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short description underneath (for example: Reading a disc meter

126 — off-peak).
Note the rating figure, the revolutions per kilowatt
• The usage in kilowatt-hours appears in the hour (r/kWh), marked on the electricity meter.
larger main display. It is usually a 6-figure
R (r/kWh as marked on meter) = 266.6
number (for example: 1253.64).
Next, with the irrigation system set up in an
When the time rate that is currently being
average position and running, time the spinning
measured is reached, the number may flash.
horizontal disc on the power meter for at least
Record this number. If none of the displays flash,
10% of R. (In this example, R is 266.6, so 10% is
record the readings from all the displays.
about 30 revs.)
Let the pump run for at least 15 minutes before
N (number of disc revolutions) = 30
taking the next reading.
T (time of test) = 386 seconds
In systems that consume large amounts of
electricity, there may be a multiplier programmed In systems that consume large amounts of
into the electronics. If so, it will be noted on the electricity, the disc may be geared down so it
electricity supplier’s bill for this meter as ‘Mult’ or doesn’t run too fast. If so, you will notice a
‘M’ and the display may read to a couple of multiplier ‘M’ is marked on the meter.
decimal places. If there is a multiplier, run the
M (multiplier as marked on meter) = 40
pump for at least 30 minutes before taking the
second register reading. From this data you can calculate the power
usage in kilowatts.
If the second reading has not changed, you are
reading the wrong register. Power usage
Reading an electronic meter =
N x 3600 x M
1st reading (register 126) = 1253.64 kWh
RxT
2nd reading (register 126) = 1254.16 kWh =
Multiplier stated on power bill = 40 30 x 3600 x 40
Power usage 266.6 x 386
= 42 kW
=
(1254.16 – 1253.64)× 40 × 3600
1800 (no. secs in 30 mins) In this example, the pump uses 42 kW.
= Perform this test regularly, over a season or
0.52 × 40 × 3600 between seasons, to check the pump’s power
1800 consumption. If you find that it takes less time for
= 41.6 kW the same number of disc revolutions than when
you first tested the pump, the power use is
higher, and you will need to find out why.
Disc meters This comparison is only possible when the
Disc Power Meter irrigation is set up in the same position as the
initial test, with the same number of sprinklers,
and with the pumping water level roughly the
same.
Multiple disc meters
If there are three meters, for example, one for
each phase of a 3-phase power supply, measure
the three meters individually and add the kW
figures together.
Note: Measuring each meter separately gives an
accurate answer. Rarely are three meters exactly
the same.
If a very accurate result is needed, you need to
monitor the system over all the irrigation positions

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for one complete cycle. In this case you need to the sprinklers are the same model and size can
record the total electricity used, the total hours of be estimated by measuring the sprinkler
use and the total amount pumped over the discharge.
period.
Use several sprinklers: at least one at the start of
the line, one in the middle and one at the end.
Step 2: Measure the flow rate (Q)
Record how long each sprinkler takes to fill a
The second measure needed to calculate container (for example, a 10-litre bucket or a 20-
pumping cost per megalitre is the flow rate of the litre drum).
system (Q).
To find the flow rate of each sprinkler in L/s,
The flow rate is the amount (or quantity) of water divide the container volume (in litres) by the time
pumped in a certain amount of time, usually required to fill it (in seconds). You can then find
given in litres per second (L/s). It should be the average for the sprinklers you measured.
measured after the system has had sufficient
time from start-up to be running normally. To calculate the total flow rate of the system,
multiply the average by the number of sprinklers
Measure the flow rate by reading your water operating.
meter at the pump for preferably the whole
irrigation cycle or at least half an hour and First sprinkler takes 9 seconds to fill a 10-litre
dividing the litres pumped by the time in seconds. bucket = 10 ÷ 9 = 1.11 L/s
Middle sprinkler takes 8 seconds to fill a 10-litre
bucket = 10 ÷ 8 = 1.25 L/s
Water Meter
End sprinkler takes 7 seconds to fill a 10-litre
bucket = 10 ÷ 7 = 1.43 L/s
Average flow = (1.11 + 1.25 + 1.43) ÷ 3
= 1.26 L/s
There are 46 sprinklers operating, so the total
flow rate is = 1.26 x 46 = 58 L/s

Step 3: Calculate the power per

megalitre pumped
From the power usage and the flow rate, the
kilowatt-hours per megalitre (kWh/ML) for your
pump can be calculated.
This is called the ‘calibration’ value (the value
used where no water meter is installed and
electricity meter readings are read to infer the
amount of water used).
Pump calibration (kWh/ML)
Water meter reading at start: 1108.345 kL = kW ÷ (Q x 0.0036)
Water meter reading after 35 minutes: 1230.145 = 42 ÷ (58 x 0.0036)
kL = 201.1 kWh/ML
Q= (Note: 0.0036 converts kilowatt-seconds per litre
(1230.145 – 1108.345) x 1000
to kilowatt-hours per megalitre.)
35 x 60
= Step 4: Calculate the pumping cost
121 800
Having calculated the power used to pump a
210 megalitre, if you know the cost per kWh, you can
= 58 L/s calculate the cost of pumping.
Note: The charges per kWh may be difficult to
Estimating flow rate by discharge work out exactly if your supplier has different
rates for day or night, weekends, and so on.
If no water meter is fitted or it is losing accuracy,
Contact your supplier for help to work this out.
the flow rate of a spray irrigation system where all

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Pumping costs that is, water level to water level, plus the losses
If supply costs 25 cents per kWh: due to friction in the suction pipe.)

Pumping cost = 201 kWh/ML x $0.25 a. Measure the Discharge (or Delivery)
Head
= $50.25 per ML
This is the pressure read from the gauge fitted at
Some typical pumping costs for a range of the pump when the system is at full operating
irrigation systems are shown in Appendix 1. pressure. This reading needs to be converted to
equivalent metres of head. (This is sometimes
Measuring pump efficiency called Pressure Head.)
Irrigation pump efficiency is a measure of how TIP: New pumps usually have a pressure gauge
well the pump converts electrical energy into installed but they often suffer physical damage
useful work to move water. The aim of careful quickly. A better method is to fit an access point
pump selection and regular pump maintenance is on the delivery side of the pump where you can
to have the pump performing as efficiently as temporarily install a pressure gauge whenever
possible (ie moving the most water for the least you want to take a reading. The gauge can be
energy required). Efficient pump operation easily detached when not needed.
minimises running costs per megalitre pumped.
A change in the pump operating pressure
Pump efficiency of 70% to 85% should be through the season or across seasons, when
achievable in most circumstances. An acceptable irrigating the same block or shift, immediately
minimum for a centrifugal irrigation pump is 65%, tells you something has changed. A sudden
and 75% for a turbine pump. An efficiency figure reduction usually indicates a new leak or a
below these means either the wrong pump was blockage on the suction side; a gradual reduction
chosen for the job, the pump is worn and needs usually indicates wear of the impeller or sprinkler
repair or maintenance is needed. nozzles; and an increase usually suggests a
blockage somewhere in the system downstream
The key to containing your pumping costs is to
of the pressure gauge.
regularly monitor your energy usage and check
on any significant change that suggests attention Pressure can be thought of as equivalent to a
is needed. pipe of water of a certain height in metres. This is
referred to as ‘head’ (H). At sea level, the
To calculate pump efficiency, you need to know
pressure at the bottom of a pipe of water 10
the flow rate (Q) and the pump pressure, or
metres high is about 100 kilopascals (kPa).
total head (H or TH) of the system. The
pressure and flow that a pump is working at is Head Pressure
called the duty or duty point. Pump efficiency
varies over the range of possible duties for any
specific pump. 5m 50 kPa

When you have calculated the pump duty, you

10 m 100 kPa
can compare it to the manufacturer’s
specifications shown in the pump’s
performance curves. The two efficiency figures 15 m 150 kPa
can then be compared to see if there is room
for improvement and therefore possibly a 20 m 200 kPa
reduction in costs.
25 m 250 kPa
Step 5: Determine Total Head
Total Head (TH or H) or Total Dynamic Head 30 m 300 kPa
(TDH) is the Discharge Head plus the Suction
Head.
(For surface irrigation systems, skip Step 5. If your pressure gauge reads only in psi, convert
An adequate estimate of total dynamic head for to kPa by multiplying by 6.9.
surface systems is the vertical height in metres
from source water level to the end of the Example:
discharge pipe, or, if the discharge is submerged, 40 psi = 40 × 6.9 = 276k Pa = 27.6 m head
to the height of the water above the discharge,

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b. Determine the Suction Head an electrical engineer.

Suction head is the distance between the centre
Step 7: Determine transmission losses
line of the pump and the source water level, plus
losses in the suction pipe if the pump is
(Df)
positioned above the water level. Typical suction If the engine is not directly coupled to the pump,
head figures for centrifugal pumps are 3 to 5 there is a loss of energy through the
metres. transmission.
Most problems with pumps positioned above the This loss is taken into account by what is termed
water level occur in the suction line, so ensure the drive factor (Df).
everything is right here. Common problems
include blocked inlet or foot-valve or strainer, Transmission type Energy transmitted Df
pipe diameter too small, pipe damaged or V-belt drives 90% 0.9
crushed, suction height too great, or air trapped
at the connection to the pump. Gear drives 95% 0.95

Turbine and axial flow pumps must be Direct drive 100% 1.0
submerged to operate, so they usually do not
have any suction head. Step 8: Calculate pump efficiency (Pe)
Example: Pressure Head = 27.6 m Pe = (Q × H) ÷ (power consumed × Me × Df)
Suction head = 4.0 m
Total Head = 31.6 m This example includes the data from the
Another useful figure that can now be calculated previous steps we have discussed. The drive
is the pumping cost per ML per metre of head. from the motor to the pump is a V-belt in this
This allows a meaningful comparison between case.
different pump stations. Pe (%) = (Q × H) ÷ (power × Me × Df)
Pumping cost per ML per metre head: = (58 × 31.6) ÷ (42 × 0.9 × 0.9)
= cost ($/ML) ÷ TH (m) = 1832.8 ÷ 34.02
= $50.25/ML ÷ 31.6m = 53.9%
= $1.59 / ML / m head
Step 9: Calculating potential $ saving
Step 6: Determine motor efficiency Most centrifugal pumps are designed to operate
(Me) with at least 75% efficiency, and most turbine
Electric motors have an efficiency value. That is, pumps are designed to operate with at least 85%
they lose some of the energy going into them as efficiency.
heat. The pump in our example is only about 54%
This energy loss changes with the size of the efficient. How much would be saved by improving
motor. The table below is a guideline for motors the efficiency from 54% to 75%?
operating at full load. Our pumping cost is $50.25 per ML. The
improvement is calculated as follows:
Power rating Approximate motor efficiency
Cost saving per ML:
Below 5 kW 82% (0.82)
= $50.25 – (50.25 x (54 ÷ 75))
5 to 15 kW 85% (0.85)
= $50.25 – (50.25 x 0.72)
15 to 50 kW 88% (0.88)
= $50.25 – 36.18
50 to 100 kW 90% (0.90)
= $14.07
>100 kW 95% (0.95)
If 900 ML are pumped during a season, the total
Submersible motors lose about 4% more than cost saving is $14.07 × 900 = $12,663.
air-cooled electric motors (for example, where Me If impeller wear is the problem and the cost of
is 88% for an air-cooled motor it would be 84% replacement is $10,000, it would be paid for in
for a submersible). less than one season. After that, the savings are
all increased profit.
Voltage losses through long electrical cables may
also be significant. This should be checked with

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Notice that a reduction in the pump efficiency they eliminate the need for throttling the irrigation
figure of 21% (75% to 54%) causes an increase system using valves.
in pumping cost of 39% ($36.18/ML to
Savings of one quarter of the usual power
$50.25/ML).
consumption are often reported by irrigators, and
may be as much as half depending on the
Other factors that affect cost and
situation.
pump efficiency
Two other variables affect cost and pump For determining the cost and efficiency of a
efficiency: pump speed and impeller size. pump, the measurements outlined in this
Primefact should be made several times with the
Pump speed pump set at different typical speeds.
You must know the pump speed in order to read Impeller size
the pump curves. The curves are usually
prepared for specific pump speeds and impeller Impeller wear has the same effect as a reduction
sizes. in impeller size.

• If the pump is directly coupled to the electric You need to know the size of impeller fitted to
motor, the speed is fixed by the speed of the your pump to work out which performance curve
motor: 2-pole motors run at 2900 rev/min and applies to your pump. Sometimes the impeller
4-pole motors run at 1440 rev/min. size is stamped on the pump’s ID plate. If not,
you need to find out the size by dismantling the
Note: Because the speed of electric motors pump and measuring it, or asking the person who
varies a little, it would be good to check your made the change.
motor speed with a rev counter.
Sometimes an impeller is deliberately reduced in
• If the motor is not directly coupled to the diameter to adjust the pump’s performance and
pump, the speed is altered by the gearing obtain a specific duty.
ratio of the transmission. Gear drives
normally have the ratio stamped on the To give a range of duties, manufacturers may
identification plate. offer impellers of different diameters for the same
pump casing.
• The ratio for a V-belt and pulley drive can be
Available impeller sizes are shown on the pump
calculated from the diameter of the pulleys
curves.
on the motor and the pump (see the diagram
below – ensure the pump is stopped before Power factor
measuring the pulleys). Power factor may substantially affect your
running costs and perhaps the operation of your
pump as well. This is not an intrinsic factor of the
pump itself, but information is provided in
Appendix 2.

In conclusion
Keeping track of your pump’s performance and
costs is not difficult. It may save you a lot of
rpm of pump = rpm of motor × diameter of motor pulley money and keep your irrigation system
÷ diameter of pump pulley performing properly
Worksheets are included with this Primefact to
help you measure your pump performance and
A complication for working out the cost and
efficiency. If you identify your pump is operating
efficiency is Variable Speed Drives (VSD), also
below the acceptable minimum level, check the
known as Variable Frequency Drives (VFD).
internal condition for wear or maintenance and
They are becoming increasingly popular as their
the suitability of the pump for its current duty, or
price reduces and for the benefits they offer.
take steps to improve the drive or replace it with
These units are added to electric motors and
a VSD.
allow the speed to be altered by changing the
frequency of the alternating current. They allow
electrically driven pumps to have their speed set
at exactly what is required for the pump duty and

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More information
Primefact 1411 Selecting an irrigation pump
Origin Energy
http://www.originenergy.com.au/files/EnergyFact
Sheet-PowerFactorCorrection2008.pdf

Acknowledgements
Edited by Peter Smith, Development Officer –
Broadacre, Tamworth
This Primefact replaces two AgFacts:
Agfact E5.10, first edition, January 2003, Peter
Smith and Alan Richards Irrigation Officers,
Tamworth and Paterson
Agfact E5.11, first edition November 2003, Alan
Richards, Irrigation Officer Maitland, and Peter
Smith, Irrigation Officer Tamworth

© State of New South Wales through the Department of Trade and

Investment, Regional Infrastructure and Services 2015. You may copy,
distribute and otherwise freely deal with this publication for any
purpose, provided that you attribute the NSW Department of Primary
Industries as the owner.
Disclaimer: The information contained in this publication is based on
knowledge and understanding at the time of writing (June 2015).
However, because of advances in knowledge, users are reminded of
the need to ensure that information upon which they rely is up to date
and to check currency of the information with the appropriate officer of
the Department of Primary Industries or the user’s independent
adviser.
Published by the NSW Department of Primary Industries.

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Appendix 1: Typical costs

Typical Electric Pumping Costs for Different Irrigation Systems ($/ML)

Total Head Electricity Cost per kWh

Irrigation System
(m) $0.25 $0.30 $0.35 $0.40

Flood Furrow 10 11.31 13.57 15.83 18.10

Lateral Move 30 33.93 40.72 47.50 54.29

Centre Pivot 60 67.86 81.43 95.00 108.58

Drip 50 56.55 67.86 79.17 90.48

Spray line 55 62.21 74.65 87.09 99.53

Traveller - Medium Pressure 70 79.17 95.00 110.84 126.67

Traveller - High Pressure 100 113.10 135.72 158.34 180.96

Appendix 2: Power factor

With alternating current (AC) electrical power, both the voltage and the current (amps) alternate polarity
between positive and negative. At the power generator, both the volts and the amps are alternating at the
same time. However, during each alternating cycle, depending on the type of load, some energy is temporarily
stored in electric or magnetic fields and returned to the power grid a fraction of a second later. Appliances with
resistive electrical loads (such as heaters, stoves, etc.) have no effect on the timing of the amps and voltage in
each cycle. This means the power generated is the same as the power used by the appliance, and the power
factor is 1.0. But appliances with inductive loads (such as transformers, motors, etc. – anything with a type of
wound coil) cause the amps to lag the voltage. When this occurs, some of the power generated is not
available for the appliance to use, so the power factor is less than 1.0.
The appliance still requires its full power demand so the extra power has to be generated and transmitted
down the system. The consequence is that the consumer is charged for this extra power. It also means that
the transmission system must have enough capacity for the higher power ie. higher capacity cables and
components. If the sustained power factor is low enough, the extra power required may overload the cables,
connectors, etc. so power companies may refuse to supply electricity to consumers with poor power factor. If
the available power becomes sufficiently low, voltage drops may be experienced. Excessive voltage drops can
cause overheating and premature failure of motors and other inductive appliances.
For electric induction motors specifically, low power factor results by running them lightly loaded. A motor
must be operated near its rated load in order to realize the benefits of a high power factor design. Power
factor is also improved by not operating equipment above its rated voltage, and by replacing standard motors
with energy-efficient motors.
Until recently, determining the power factor required specialist measurements. Now, there are meters
available that provide the power factor on the spot. Unfortunately, power factors measured in irrigation farms
of 0.8 or less are common.
A power factor of anywhere between 0.9 and 1 means your business is using its energy effectively. However a
power factor of below 0.9 may mean your business is using energy ineffectively, resulting in unnecessary
electricity expenses. A figure of 0.95 is considered a practical maximum.

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The good news is that poor power factor can be corrected. Where inductive loads cause the amps to lag the
voltage, capacitance loads cause the amps to lead the voltage. Capacitors store and release energy in a
directly opposite manner to an inductor. When the circuit is balanced, all the energy released by the inductor
is absorbed by the capacitor. A capacitor provides the power that is needed to start up and magnetize the
motor, thus eliminating the need to get it from the electric grid.
Power factor can be improved by installing Power Factor Correction equipment called Capacitor Banks.
Capacitor Banks work to correct energy supply inefficiencies and reduce peak demand on the electricity
network.

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PUMPING COSTS WORKSHEET – ELECTRONIC METER

Electricity meter Worked example Your readings Your readings

1. Register reading at start (R1) 1253.64

2. Register reading at finish (R2) 1254.16

3. Time between readings (T) 1800 seconds (30 min)

4. Multiplier as stated on power bill (M) 40

5. kW per meter = 0.52 × 3600 × 40

= (R2 - R1) × 3600 × M 1800
T = 42 kW

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PUMPING COSTS WORKSHEET – DISC METER

Electricity meter Worked example Your readings Your readings

1. R/kWh as marked on meter (R) 266.60

2. Multiplier as marked on meter (M) 40

3. Number of disc revolutions (N) 30

4. Time duration (T) 386 seconds

5. kW per meter = 30 × 3600 × 40

= N × 3600 × M 266.6 × 386
R×T
= 42kW

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PUMPING COSTS WORKSHEET – CONTINUED

Worked example Your readings Your readings

6. Flow rate (Q) 58 Litres per second

7.Pump calibration = = 42 kW
kW 58 × 0.0036
Q x 0.0036 = 201 kWh/ML

8.Pumping costs = 201 × $0.25

(@ 25 cents/kWh) = $50.25 per ML

PUMP EFFICIENCY WORKSHEET

Worked example Your readings Your readings

1. Power consumption (kW) 42 kW

2. Flow rate (Q) 58 L/s

3. Pressure gauge at pump 276 kPa x 0.1 = 27.6 m

4. Suction lift 4m

5. Total head (H) = 27.6 + 4.0 = 31.6 m

6. Motor efficiency (Me) 70 kW motor = 0.9

7. Transmission loss (Df) V-belt = 0.9

8. Pump Efficiency (Pe) = __58 × 31.6__

Pe = ___Q × H____ 42 × 0.9 × 0.9
kW × Me × Df
= 53.9%

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