Report to the OREGON PROCESSED VEGETABLE COMMISSION
Project: Energy audits to identify opportunities for processed vegetable growers to save
electricity, fuel, and fertilizer
Prepared: December 21, 2009
Principal Investigator:
Joe Junker,
Director, OSU Energy/Efficiency Center
Assistant Director, OSU Industrial Assessment Center
344B Batcheller Hall, Corvallis, Oregon, USA 97331-2405
Voice: 541/737-5034 Fax: 541/737-5035
Email: junkerj@engr.orst.edu
Project Summary:
This project got off to a late start. The Energy Efficiency Center (EEC) did not receive
notice that this project was funded until this fall. A University Index for the project was
set up November 6th. It was unfortunate that the opportunity to work on the project
through summer growing season and greatest center staff availability was missed, but
the team has taken the opportunity to focus more on audit tool preparation.
With a fall start, the team decided the best strategy would be to begin by preparing an
instrument for use in performing efficiency assessments of processed vegetable
growing operations. The goal: to develop a comprehensive list of likely efficiency
opportunities that might be found in the processed vegetable growing sector, along with
templates for analyzing and presenting opportunities. As it is prepared, this content is
being put on line for use by EEC staff as well as the general public. It can be found at:
http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Sectors/Processed_Vegetables
Some of the content that has been developed is included at the end of this report.
Plans going forward:
With a continuation of this project the EEC plans to
• Continue assessment tool development
• Meet with stakeholders to review the tool and solicit feedback on refinements
• Perform 1-2 assessments of appropriate operations.
Financial Information:
Total granted amount: $9,933.00
Spent to date (12/21/2009): $4,099.25
Attached: Example assessment instrument content (in development)
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(This section is under development
with
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the
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Oregon
Processed Vegetable Commision.)
This guide serves as an aid for assessing energy efficiency at
farms growing vegetables.
Industry Primer
Vegetable growers, as the name implies, are part of an
agricultural industry
that focuses on the
growing and
harvesting of vegetables. The grower's harvest or output can be
Sent to processors who might either freeze, can, or dehydrate the vegetables or use
them as an ingrediant in another product
Sold to a distributor
Marketed directly to resturants and local markets and/or at farm stands and farmer's
markets
Common Opportunities
Following is a list of common energy efficiency opportunities found at vegetable growing
operations including background information and tools to make simple and detailed
calculations of energy savings
System
Opportunity & Background Information
Fuel Storage
Reduce Fuel Evaporation
Tractor
Tractor Operation
Analysis Tools
Tractor Operation.doc
Tractor Maintenance
Soil
Amendments
People Movers
Irrigation
GPS Application Control
Use Less Fuel Intensive People Movers (Gator
Style, Electric, Bicycles)
Electric People
Movers.doc
Improve Pump Efficiency
Reduce Line Losses
Low-flow Irrigation
Low Pressure
Irrigation.doc
Irrigate Only as Needed (Moisture Sensing)
Refrigeration
Improve Refrigeration Efficiency
Improve Refrigeration Insulation
Greenhouses
Greenhouse Insulation
Greenhouse
Insulation.doc
Section off Idle Space
Heater Efficiency
Ventilation Control
Buildings
Furnace Efficiency
Boiler Tune.doc
Wall Insulation
12/21/2009 3:17 PM
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http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Sectors/Processed...
Attic Insulation.doc
Attic Insulation
Efficient Windows
Lighting
Lighting Efficiency
Lights Off
Electric
Generation
Solar Generation
Wind Generation
Oregon Vegetable Growers
In Oregon, the major processed vegetable crops are green beans, carrots, broccoli,
cauliflower, sweet corn, and table beans. The principal finished products are frozen, canned,
and microwavable mixed vegetables. The Oregon Processed Vegetable Commission includes
eight growers and three processors. The commission provides funds to farmers for productoriented projects and hosts an annual meeting for growers at the end of January.
Production of canned vegetables has dropped significantly. Global competition has become a
major issue for Oregon vegetable processors. As a result of this competition, the price of green
beans has fallen sharply from $89 to $110/ton in 2001. Fewer than 10 percent of vegetables
are exported because of a lack of marketing strategies and contacts.
Additional Information
Following are additional resources regarding energy efficiency in the vegetable growing sector.
Websites
Oregon Processed Vegetable Comission
Reports
"Energy Usage in the Food Industry",
ACEEE
"Understanding the Oregon Fruit
& Vegetable Industry", OPVC
Retrieved from "http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Sectors
/Processed_Vegetables"
12/21/2009 3:17 PM
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Fuel is a major cost on
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modern farms, especially
with the continually rising fuel prices. Therefore it is important to find ways to conserve fuel
and reduce associated operating costs. This page provides a number of measures that will
reduce fuel consumption and costs. This page also contains tools to help estimate the amount
savings that may be available.
Tractor Operation
Tractors play a important role in most modern farms,
and are used for a wide variety operations and
procedures. Operators can obtain a number of
speeds by adjusting the transmission gear ratio while
maintaining the same engine RPM. Within each gear
ratio there is further adjustment available with the
governor setting lever (or the idler lever if the
tractor doesn't have a governor). In most cases
tractor field speeds are determined by the implement
and not by the tractor power available. Most
operators run tractors at full throttle using the
transmission gear ratio to vary speed. Significant
increases in fuel efficiency are expected if the
governor speed is reduced and a faster gear ratio is
selected. This is particularly true in cases where the tractor and equipment are not properly
matched and the tractor is operating at less than half load.
Listed below are some useful measures on how to increase fuel efficiency while reducing
associated fuel costs.
The engine speed should be reduced as far as possible while staying in its designed
power range. Check the operators manual to find the engines power range. Generally,
it is save to reduce engine speed by a maximum of 30 percent without getting out of the
power range. Operating a tractor outside side of its designed power range will only
decrease fuel efficiency and increase fuel consumption.
It is important to not overload or lug the tractor. Lugging the tractor causes the engine
to generate more torque at low engine speeds then it was designed for. This can result
in engine overheating and in some extreme cases, engine failure. Key indicators to
overloading is excessive black smoke, or the tractor is sluggish in response when
throttled up to full throttle. The tractor should accelerate quickly when throttled up, if it
doesn't, the engine RPMs should be increased until the engine becomes responsive to
quick throttle change.
Only reduce throttle during non PTO operations unless the tractor is equipped with a
variable speed PTO that can keep its speed with reduced engine RPMs.
To help you easily determine the amount of savings that may be available to your agricultural
operation, we have developed a energy estimator tool located below. Results may not
represent your actual savings but should give a fairly accurate rough estimate. We
recommend you consult a specialist before implementing any actions recommended above to
12/21/2009 3:17 PM
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confirm your savings.
Tractor Governor Estimator
......................................................................................
Horsepower of Tractor :
hp
Hours of Operation :
hrs/yr
Fuel Cost :
$/gal
......................................................................................
Estimated Fuel Savings :
0 gallons
Estimated Annual Savings :
0 dollars
......................................................................................
Calculate
Clear
Gadgets powered by Google
For more details refer to the following sample recommendation. It includes a more in depth
approach as well as actual savings and cost calculations. Adobe Acrobat Reader is required to
view these files. You can download the program for free.
Tractor Operation AR (KB)
Listed below are some useful links and documents with more information.
Gear Up and Throttle Down -- Saving Fuel
Gear-up and Throttle Down to Save Fuel
Farmers Can Save Big Money On Fuel
Farm Power and Machinery Management
Tractor Maintenance
Tractors are a key component to most agricultural
operations, yet when it comes to maintaining them,
they are often neglected. This can lead to premature
wear on critical engine components and shorten
there useful life. This can also lead to significant
loses in fuel efficiency particularly on older tractors.
Tractors should be maintained as specified in there
operators manual to get the most out of them. This
will help increase there useful life and fuel efficiency
while decreasing the number of costly breakdowns
that occur during the operating season. This will also
increase the power output while minimizing the
amount of harmful exhaust emissions released into
the atmosphere.
Listed below are some measures that will increase fuel efficiency and keep tractors in top
condition while reducing associated fuel costs.
Check tire pressure weekly - Under inflated tires can not only prematurely wear tires
giving them a shorter life but can also decrease fuel efficiency by 3 percent. Over
inflated tires can cause excessive slip decreasing fuel efficiency by 3 percent. Check tire
pressures weekly as pressure can change when exposed to work intensive tasks. Check
your operators manual for correct inflation pressures.
Check and replace oil and fuel filters seasonally - Clogged or dirty filters can not
only harm the engine but also decrease fuel efficiency by up to 5 percent. Replace filters
as recommended by operators manual.
Check and clean air filters weekly and replace as needed - In some extreme
cases, a dirty air filter can decrease fuel efficiency by up to 20 percent. Check, clean
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and change air filters as recommended by operators manual.
Check ballast weight on implement change - Properly ballast the tractor to reduce
slip, power hop and weight. Excessive weight can increase fuel consumption so it is
important to reduce weight as much possible while still maintaining good traction,
balance and handling characteristics. Tire slippage should be kept to a minimum,
between 5 an 15 percent for work intensive tasks is usually good. Check operators
manual for more details.
Check thermostat is properly functioning - Engines are most efficient when
operating with a water temperature between 165 and 180 degrees F. Fuel efficiency can
decrease by 25 percent when operating at 100 degrees F. Make sure tractors
thermostats are operating correctly and not over or under cooling the engine.
Use engine block heaters before operation - Using engine block heaters that are set
on timers to preheat the engine a couple hours before use can reduce wear on key
engine components. Most engine wear happens on start up when the engine and fluids
are cold. By heating the engine prior to start up, this wear can be avoided extending the
useful life of the engine and keeping failures to minimum.
Check spark plugs - On gas models a fouled spark plug can decrease fuel efficiency
between 10 and 15 percent. It is important to check all plugs regularly for a strong
spark.
Check proper fitting fuel caps - Improper fitting fuel caps can leak fuel. Make sure
the fuel cap is properly tightened after every fill up and replace any broken or worn
seals.
Avoid excessive road use - Excessive road use can prematurely wear tires giving
them a shorter life. Worn tires also get significantly less traction reducing fuel efficiency.
Use correct size tractor for implement - Using an over sized tractor for the
implement can reduce fuel efficiency. If the tractor can be significantly throttled down
while still performing the task it is a good sign that it is over sized and a smaller tractor
should be used.
Upgrade to more efficient models when replacing tractor - When buying a new
tractor it is best to buy an efficient one even if it cost slightly more. The increase in
efficiency will quickly pay for itself.
Avoid quick starts - Engines need to warm up to operating temperatures before
worked excessively to reduce the wear on the engine. This is because the engine oil
needs to be warmed up and circulated throughout the engine to give proper lubrication.
Quick starts don't give the engine enough time to do this causing excessive wear.
Have wheels aligned and balanced - Properly aligned and balanced tires decrease
the overall rolling resistance of the tractor increasing fuel efficiency. Check your
operators manual for more details.
To help you easily determine the amount of savings that may be available to your agricultural
operation, we have developed a energy estimator tool located below. Results may not
represent your actual savings but should give a fairly accurate rough estimate. We
recommend you consult a specialist before implementing any actions recommended above to
confirm your savings.
12/21/2009 3:17 PM
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Tractor Maintenance Schedule Estimator
......................................................................................
Horsepower of Tractor :
hp
Hours of Operation :
hrs/yr
Fuel Cost :
$/gal
Check Tire Pressure Weekly :
No
Replace Oil/Fuel Filters Seasonally :
No
Clean Air Filters Weekly :
No
Adjust Ballasting to Implement :
No
......................................................................................
Estimated Fuel Savings :
0 gallons
Estimated Annual Savings :
0 dollars
......................................................................................
Calculate
Clear
Gadgets powered by Google
For more details refer to the following sample recommendation. It includes a more in depth
approach as well as actual savings and cost calculations. Adobe Acrobat Reader is required to
view these files. You can download the program for free.
Tractor Maintenance AR (KB)
Listed below are some useful links and documents with more information.
Let The Air Out! Advantages of Properly Adjusted Radial Tire Pressures
Proper Tractor Setup Can Increase Fuel Efficiency
Conserving Fuel on the Farm
Saving Fuel On The Farm
Saving Fuel In Field Operations
Fuel Storage
Storage tanks are often taken for granted and are
assumed to have no loses, which is simply not true.
And with toady's continually rising fuels costs it has
become more important than ever to pay close
attention to your facilities storage tanks. Storage
tanks can lose a considerable amount of fuel due to
evaporation and unnoticed leaks. In extreme cases
up to 40 percent of a tank’s capacity can be lost per
year through evaporation in above ground tanks
while many leaks continue to go unnoticed in
underground tanks. This is not only wasteful and
costly but also harmful to the surrounding
environment. It is important to recognize that these
problems don't have to occur and that they can be
easily fixed.
Listed below are some measures that will keep storage tank loses to a minimum, reducing
associated fuel costs.
Reflective surface finish - Fuel in tanks slowly evaporates to atmosphere when
exposed to higher temperatures. Darker colors absorb more light/heat then lighter
colors which reflect light/heat. Using aluminum finish or white tanks can significantly
decrease the heat absorbed by the tank lowering its internal temperature. This will help
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reduce the amount of fuel that vaporizes to atmosphere saving fuel.
Protective covering - Tanks should be kept out of direct sunlight to reduce the amount
of fuel that vaporizes. Either burying the tank or putting a protective roof over the tank
can solve this although burying the tank is not recommended because leaks can go
unnoticed increasing fuel lost.
Pressure relief cap - Most older fuel tanks simply vent to atmosphere through a small
vertical pipe. Installing vacuum pressure relief caps on the vents can reduce the amount
of fuel vapors released from the tank while still allowing air to flow into the tank.
Lock unattended fuel tanks - Fuel tanks tanks should be kept locked at all times. It is
not uncommon for workers or neighbors to fill up if tanks are left unlocked.
Regularly inspect tanks - During inspections tighten all fittings and check for leaks and
properly functioning valves. It is important to keep leaks to a minimum to help protect
the environment and your wallet.
Install motion sensor lighting - Sometimes a simple motion sensing light directed at
the tank is enough to deter thief's from trying to steal fuel. It is a simple and effective
way to deter unwanted guests.
Clearly label farm diesel tanks - Labeling tanks "Red Diesel" can further deter thief's
and prevent on farm mix ups. Putting farm diesel in highway vehicles is illegal and can
result in a large fine.
To help you easily determine the amount of savings that may be available to your agricultural
operation, we have developed a energy estimator tool located below. Results may not
represent your actual savings but should give a fairly accurate rough estimate. We
recommend you consult a specialist before implementing any actions recommended above to
confirm your savings.
Fuel Tank Estimator
......................................................................................
Fuel Tank Size :
gallons
Fuel Cost :
$/gal
Type of Finish :
Red
Tank Location :
Uncovered
Pressure-Relief Cap :
No
......................................................................................
Estimated Fuel Savings :
0 gallons
Estimated Annual Savings :
0 dollars
......................................................................................
Calculate
Clear
Gadgets powered by Google
For more details refer to the following sample recommendation. It includes a more in depth
approach as well as actual savings and cost calculations. Adobe Acrobat Reader is required to
view these files. You can download the program for free.
Fuel Storage AR (KB)
Listed below are some useful links and documents with more information.
Conserving Fuel on the Farm
Retrieved from "http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Energy_Efficiency
/Conserving_Fuel"
12/21/2009 3:17 PM
Efficient Irrigation - Energy Efficiency Reference
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Irrigation accounts for a
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substantial portion of a
typical farmers electric bills. Therefore it is important to find ways to conserve water and
reduce associated operating costs. This page provides a number of measures that will
increases irrigation efficiencies and reduce associated operating costs. This page also contains
tools to help estimate the amount savings that may be available.
VSD Irrigation Pump
Most irrigation pumps run at full speed no matter the
load on the system. This is very inefficient
particularly when a wide range of flows rates and
pressures are needed through out the season. A
more energy efficient system uses a variable speed
drive (VSD) to slow the motor speed to match the
end use requirements. This will maintain the same
pressure while reducing the flow rate and energy
consumption of the pump. A VSD will also allow
pumps to "soft start", by slowly ramping up the
motor instead of trying to do so instantaneously. This
will ensure the peak demand is never more than the
motors full load operating amps, reducing associated
demand costs. This will also reduce motor wear and
damage caused by hard starting as well as maintenance cost associated with water
surge/hammer and sprinkler head damage.
Listed below are some situations when a VSD controlled irrigation system will be cost effective.
Pumping systems implementing bypass or throttling control valves.
Pumping systems that draw from a well with a depth that varies significantly.
Pivot and linear systems that have a end gun that turns on and off at varying locations in
the field.
Pivot and linear systems located on terrain that has elevation changes.
Pumps that service multiple systems that may not all be on at once.
To help you easily determine the amount of savings that may be available to your agricultural
operation, we have developed a energy estimator tool located below. Results may not
represent your actual savings but should give a fairly accurate rough estimate. We
recommend you consult a specialist before implementing any actions recommended above to
confirm your savings.
12/21/2009 3:18 PM
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VSD Irrigation Pump Estimator
......................................................................................
Horsepower of Motor :
hp
Hours of Operation :
hrs/yr
Energy Cost :
$/kWh
......................................................................................
Estimated Energy Savings :
0 kWh
Estimated Annual Savings :
0 dollars
......................................................................................
Calculate
Clear
Gadgets powered by Google
For more details refer to the following sample recommendation. It includes a more in depth
approach as well as actual savings and cost calculations. Adobe Acrobat Reader is required to
view these files. You can download the program for free.
VSD Irrigation Pump AR (KB)
Listed below are some useful links and documents with more information.
Farmer Finds Efficiency in Drive-Driven Irrigation
Irrigation Energy Efficiency Analysis
Energy Saving Tips for Irrigators
Low Pressure Irrigation
Most irrigation systems utilize a high pressure
sprinkler system to deliver water to the field. These
system typically operate from 70 - 100 psi. This is a
very inefficient method for delivering water to a field.
A more energy efficient system uses low pressure
drop down nozzles that require less pressure to
operate at the same flow rate as conventional
sprinklers. These low pressure systems can operate
at pressures as low as 15 - 20 psi without a reduction
in flow rate. This puts less load on the pump, by
installing a variable speed drive (VSD), the pump is
then able to change how it operates depending on its
current load and pressure reducing energy
consumption.
Listed below are some useful tips on what types of low pressure irrigation system are most
cost effective.
Linear or center pivot irrigation systems are easily retrofitted to run at 15 psi and yield
very quick paybacks. The larger the system the more cost effective it will be.
Hand lines can be converted to semi low pressure (35 psi and sometimes lower) but are
not as cost effective because it reduces the flow rate thus increasing pumping time.
Moving guns can be retrofitted to a moving boom system and can be very cost effective
but will suffer from increased size thus limited mobility and increased chance of operator
caused damage.
To help you easily determine the amount of savings that may be available to your agricultural
operation, we have developed a energy estimator tool located below. Results may not
represent your actual savings but should give a fairly accurate rough estimate. We
12/21/2009 3:18 PM
Efficient Irrigation - Energy Efficiency Reference
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http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Energy_Efficiency/E...
recommend you consult a specialist before implementing any actions recommended above to
confirm your savings.
Low Pressure Irrigation Estimator
......................................................................................
Horsepower of Pump :
hp
Hours of Operation :
hrs/yr
System Pressure :
psi
Energy Cost :
$/kWh
Demand Rate :
$/kW
......................................................................................
Estimated Energy Savings :
0 kWh
Estimated Demand Savings :
0 kW
0 dollars
Estimated Annual Savings :
......................................................................................
Calculate
Clear
Gadgets powered by Google
For more details refer to the following sample recommendation. It includes a more in depth
approach as well as actual savings and cost calculations. Adobe Acrobat Reader is required to
view these files. You can download the program for free.
Low Pressure Irrigation AR (KB)
Listed below are some useful links and documents with more information.
Farmer Finds Efficiency in Drive-Driven Irrigation
Irrigation Energy Efficiency Analysis
Energy Saving Tips for Irrigators
Irrigation Scheduling
Over irrigation wastes water, energy and labor while
also increasing soil erosion, washing away valuable
nutrients thus reducing crop yields. These nutrients
then have to be replaced in the form of fertilizer
increasing fertilizer costs. Under irrigation stresses
the plant and soil and also causes a reduction in
yield. As a general rule of thumb, irrigation should
begin when soil water content drops below 70
percent. By using moisture sensing devices, flow
rate meters, and tracking the amount of water
applied these problems can be avoided increasing
yield while keeping water and electricity usage to
minimum. On average a farm using irrigation
scheduling will consume 15 to 35 percent less water
than a farm not using it, decreasing pump run times and loads.
To help you easily determine the amount of savings that may be available to your agricultural
operation, we have developed a energy estimator tool located below. Results may not
represent your actual savings but should give a fairly accurate rough estimate. We
recommend you consult a specialist before implementing any actions recommended above to
confirm your savings.
12/21/2009 3:18 PM
Efficient Irrigation - Energy Efficiency Reference
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Irrigation Scheduling Estimator
......................................................................................
Horsepower of Motor :
hp
Hours of Operation :
hrs/yr
Energy Cost :
$/kWh
......................................................................................
Estimated Energy Savings :
0 kWh
Estimated Annual Savings :
0 dollars
......................................................................................
Calculate
Clear
Gadgets powered by Google
For more details refer to the following sample recommendation. It includes a more in depth
approach as well as actual savings and cost calculations. Adobe Acrobat Reader is required to
view these files. You can download the program for free.
Irrigation Scheduling AR (KB)
Listed below are some useful links and documents with more information.
Irrigation Scheduling to Improve Water - And Energy-Use Efficiencies
Soil Moisture Monitoring: Low-Cost Tools and Methods
Measuring and Conserving Irrigation Water
Energy Saving Tips for Irrigators
Irrigation Scheduling
Irrigation Systems
Irrigation accounts for approximately 30 percent of a
farms overall electricity usage. Following the
following tips can help reduce your water
consumption, electricity costs and labor while
improving crop yields and reliability.
Premium Efficiency Motors - When buying
new pumps buy Premium Efficiency (PE), if an
old motor needs rewinding then it may be
economically feasible to buy a new PE motor.
PE motors are between 2 and 10 percent more
efficient than standard efficiency motors.
Test Pumps Efficiency - Testing pumps
efficiency every two to three years can help
make sure that pumps are performing properly and that no significant losses are
occurring. Pumps can feasibly reach efficiencies as high as 70 percent, following are the
recommended actions for given efficiencies.
Efficiencies Above 60% - No action is necessary although efficiency may be
improved by adjusting impeller clearances.
Efficiencies Between 50% and 60% - Adjusting the impeller to housing
clearance is recommend as efficiency may increase by 10-15%
Efficiencies Between 50% and 55% - Damage to the impeller is likely and
repair is recommended as efficiency may increase by 20%
Efficiencies Below 50% - Replacement is recommended in most cases, it may
be caused by a improperly sized motor for the application, consider resizing
components for optimum efficiency.
Pipes - Using the right size pipe for the desired flow rate can significantly reduce energy
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consumption. Using 6 inch mainlines can consume 4 times as much energy as 8 inch
mainlines in some cases. When expanding or replacing your systems pipeline we
recommend consulting a professional to help analyze which sizes may be most cost
effective.
System Setup - Using proper diffusers, fitting, meters, and valves can significantly
increase your overall system efficiency. We recommend looking at the following ATTRA
publications on irrigation energy savings.
Energy Saving Tips for Irrigators
Maintaining Irrigation Pumps, Motors, and Engines
Retrieved from "http://eeref.engr.oregonstate.edu/Sectors/Agricultural/Energy_Efficiency
/Efficient_Irrigation"
12/21/2009 3:18 PM
AR No. #
Tractor Operation
Recommendation
We recommend throttling tractors down while selecting a higher gear ratio during field
operations. This will maintain the same speed while increasing fuel efficiency and reducing fuel
costs.
Assessment Recommendation Summary
Diesel
Energy
Cost
Implementation
Payback
(Gallons) (MMBtu)* Savings
Cost
(years)
1233.4
172.7
$3,071
$0
Immediate
* 1 Gallon Diesel = 0.14 MMbtu. 1,000,000 Btu = 1 MMbtu
Background
Tractors play an important role in most modern farms, and are used for a wide variety operations
and procedures. Operators can obtain a number of speeds by adjusting the transmission gear
ratio while maintaining the same engine RPM. Within each gear ratio there is further adjustment
available with the governor setting lever (or the idler lever if the tractor doesn't have a governor).
In most cases tractor field speeds are determined by the implement and not by the tractor power
available. Most operators run tractors at full throttle using the transmission gear ratio to vary
speed. Significant increases in fuel efficiency are expected if the governor speed is reduced and a
faster gear ratio is selected. This is particularly true in cases where the tractor and equipment are
not properly matched and the tractor is operating at less than half load.
Engine RPM should not be reduced so far that the tractor is out of its power range. Check your
operator’s manual to find the engine’s power range. Generally, it is safe to reduce engine speed
by a maximum of 30% without getting out of the power range. Operating a tractor outside of its
power range will only decrease fuel efficiency.
Proposal
During field operations, throttle down your
tractors while selecting a higher gear ratio. This
will increase fuel efficiency while still maintaining
the same speed. It will save an estimated 1,233
gallons of diesel a year, with a cost savings of
$3,071. Since it is simply a change in operations
there is no implementation cost and therefore an
immediate payback.
Courtesy of www.pegtopfarm.co.uk Tractor Operation
Tractor Inventory
Tractor Model
New Holland TC45
New Holland TS110
New Holland 4630
New Holland 5640
John Deere 5093E
Total
hp (HP )
45
110
55
66
93
Fuel Savings Energy Savings Cost Savings (Eq.1) (Eq.2) (Eq.3) hr/yr (OH )
(gallons)
(MMBtu)
(dollars)
250
500
250
250
250
Fuel Costs
Diesel Cost (DC )
115.9
566.5
141.6
170.0
239.5
1,233.4
16.2
79.3
19.8
23.8
33.5
172.7
Equations
$2.49
$/ga l
Eq. 1) Fuel Savings (F s )
Assumptions
Diesel Consumption Factor (CF 1 )
Throttle Reduction (TR )
Fuel Use Reduction (FR )
Diesel/MMBtu Conversion Factor (CF 2 )
Energy Saving Results
Total Fuel Savings
Total Energy Savings
0.0515
20%
20%
0.14
1,233
172.7
ga l /hp/hr
Eq. 2) Energy Savings (E s )
MMBtu/ga l
ga l l ons
MMBtu
Economic Results
Total Cost Savings
Implementation Costs
Payback
$3,071
$0
0.0
yea rs
Eq. 3) Cost Savings (C s )
288.5
1,410.6
352.6
423.2
596.3
$3,071.23
AR No. #
Electric People Movers
Recommendation
When needed, replace the current on-farm vehicle with an electric vehicle (EV). Due to the
increased energy efficiency of electric vehicles, this will reduce your energy use by the
equivalent of 506 gallons of gasoline per year.
Assessment Recommendation Summary
Energy
Cost
Implementation
Payback
(MMBtu) Savings
Cost
(years)
64.8
$945
$0
Immediate
Background
There are many unknowns and differences in maintenance for electric and gas vehicles, so we
make a simplified assumption that purchase costs are equal and over the life of the vehicle the
maintenance costs will be too. We therefore make the comparison between a gas vehicle’s fuel
cost per mile and an electric vehicle’s fuel cost per mile, along with the annual cost of batteries
for the electric vehicle.
EV technology is still developing and isn’t appropriate for all applications. We’re used to
thinking of a vehicle, like a gas pickup truck, that could move farm personnel to and from the
farm on surface streets at high speeds as well as cruise around the farm at low speeds with a load
of equipment. EVs would not be able to completely replace the pickup truck because it is not
permitted on a section of road where the posted speed limit is above 45 mph. EVs could however
replace the pickup truck’s on-farm activities—which are the most inefficient miles of a gas
vehicle. Our calculations are based on an exclusively on-farm vehicle and mileage estimates
provided by plant personnel of 15,000 miles per year.
Proposal
When the current on-farm vehicle needs to be
replaced, we recommend replacing it with an
electric vehicle, saving 54.8 MMBtu per year.
Annual cost savings is $945 with no
implementation cost and an immediate
payback.
Courtesy of www.greencarsite.co.uk
Electric People Movers
Data Collected
Miles per Gallon of Gas Vehicle (G)
Cost of Gasoline (Gc )
On‐Farm Mileage (FM)
Equations
25.0 mpg
$3.00 /gal
15,000 mi/yr
Eq. 1) Gas Vehicle Fuel Cost (GV)
Incremental Energy Data
Incremental Energy Cost (Ec )
Eq. 2) Electric Vehicle Fuel Cost (EV)
$0.0750 $/kWh
Assumptions
Battery Cost per Year (Bc )
Miles per kWh of Electric Vehicle (K)
$480
3.0 mi/kWh
Eq. 3) Cost Savings (CS)
Energy Savings Summary
Gas Vehicle Fuel Cost per Mile (GV)
Electric Vehicle Fuel Cost per Mile (EV)
$ 0.12
$ 0.025
$/mi (Eq. 1)
$/mi (Eq. 2)
Implementation Costs Summary
Implementation Cost (IC)
$0
(Rf. 1)
$945
$0
0.0 yrs
(Eq. 3)
Economic Results
Cost Savings (CS)
Implementation Costs (IC)
Payback (PB)
Rf. 1) There is no implementation cost because we recommend that when a current on‐farm gas vehicle needs to be replaced, you buy an electric vehicle.
AR No. #
Low Pressure Irrigation
Recommendation
Convert your current irrigation system to a low pressure system. This will allow the system to
operate at a lower pressure which is more efficient than the current method, and could reduce
total pump operating costs by 46%.
Assessment Recommendation Summary
Energy
Cost
Implementation
Payback
(kWh)
Savings
Cost
(years)
55,950
$4,812
$1,250
0.3
Background
Most irrigation systems utilize a high pressure sprinkler system to deliver water to a field. A
more energy efficient system uses low pressure nozzles that require less pressure to operate at
the same flow rate as conventional sprinklers. These low pressure systems can operate as low as
30 psi without a reduction in flow rate.
Energy savings will occur because the Variable Frequency Drive (VFD), that will also be
installed, will slow down the pump motor to maintain a lower pressure. As flow will remain the
same at a reduced pressure, required pump energy will drop linearly with the required pressure.
Proposal
Replace your current irrigation system
with a low pressure system with a VFD.
This will save 55,950 kWh and $4,812
annually. There is an implementation cost
of $1,250 with a payback of 0.3 years.
Courtesy of www.fas.org Low Pressure Irrigation
Data Collected
Current Pressure (CP)
Pump Horsepower (HP)
Operating Hours (HS)
Number of Sprinkler Heads (QU)
Equations
90 psi
100 hp
2,500 hrs/yr
500
Eq. 1) Proposed Pump Speed Percentage (FS)
Eq. 2) Loaded Pump Power (LP)
Incremental Energy Data
Incremental Energy Cost (Ec )
$0.086 $/kWh
Assumptions
Proposed Pressure (PP)
Estimated Load Factor (LF)
Horsepower to kW Conversion (CF)
Cost per Sprinkler Head (CU)
Installation Time per Unit (IT)
Cost of Labor (CL)
Eq. 3) Proposed Energy Consumption (PE)
60 psi
0.9
0.746 kW/hp
$0.50 $/unit
0.1 hrs/unit
$20 $/hr
Energy Savings Summary
Proposed Pump Speed Percentage (FS)
Loaded Pump Power (LP)
Proposed Energy Consumption (PE)
Current Energy Consumption (CE)
Energy Savings (ES)
Eq. 5) Energy Savings (ES)
67%
(Eq. 1)
90 hp (Eq. 2)
111,900 kWh (Eq. 3)
167,850 kWh (Eq. 4)
55,950 kWh (Eq. 5)
Implementation Costs Summary
Material Costs (MC )
Labor Costs (L C )
Eq. 4) Current Energy Consumption (CE)
Eq. 6) Material Costs (MC )
Eq. 7) Labor Costs (L C )
$250
$1,000
(Eq. 6)
(Eq. 7)
Eq. 8) Cost Savings (CS)
Economic Results
Cost Savings (CS)
Implementation Costs (IC)
Payback (PB)
$4,812
(Eq. 8)
$1,250
(Eq. 9)
0.3 yrs
Eq. 9) Implementation Costs (IC)
AR No. #
Greenhouse Insulation
Recommendation
Install a thermal insulation system on your greenhouse to reduce heat loss during the night. In a
greenhouse up to 85% of the heat loss occurs at night. These insulation systems can reduce heat
loss by 30%.
Assessment Recommendation Summary
Energy
Cost
Implementation
Payback
(MMBtu) Savings
Cost
(years)
75.3
$1,045
$2,543
2.4
*1,000,000 Btu = 1 MMbtu
Background
A large majority of a facility’s energy costs go to greenhouses because they require additional
heating during cooler months to maintain necessary conditions for research. When the
temperature difference between the greenhouse and the outside air is the greatest, heat loss can
be up to 85%. A thermal curtain insulating system can minimize heating costs by reducing the
heat loss in the greenhouse. This is especially effective during nights and winter, and can save
30% of the energy lost.
Proposal
We recommend that you install a
thermal curtain insulation system in
your greenhouse to reduce heat loss
during nights and winter months. This
will result in a cost savings of $1,045
and 30% reduction in energy use for
the greenhouse. There is an
implementation cost of $2,543
resulting in a payback of 2.4 years.
Courtesy of the Virginia Cooperative Extension Greenhouse Insulation
Data Collected
Natural Gas Usage of Greenhouse (U )
Square Footage of Greenhouse (SF )
Equations
251 MMBtu/yr
1130 s q. ft.
Eq. 1) Energy Savings (ES)
Incremental Energy Data
Incremental Natural Gas Cost (E c )
$13.88 $/Mmbtu
Eq. 2) Cost Savings (CS)
Assumptions
Percentage Reduction (PR )
30%
Eq. 3) Implementation Costs (IC)
Energy Savings Summary
Energy Savings (E S )
75.3 MMBtu (Eq. 1)
Implementation Costs Summary
Cost of Insulation per sq. ft. (I )
$2.25 $/s q. ft.
Economic Results
Cost Savings (CS )
Implementation Costs (IC )
Payback (PB )
$1,045
$2,543
2.4 yrs
(Eq. 2)
(Eq. 3)
AR No. #
Boiler Tune
Recommendation
Tune your boiler to 4% excess oxygen so that it will run at a higher efficiency, resulting in an 8%
reduction in energy use.
Assessment Recommendation Summary
Energy
Cost
Implementation
Payback
(MMBtu) Savings
Cost
(years)
835.3
$9,239
$350
0.04
* 1 MMBtu = 1,000,000 Btu
Background
When a boiler burns fuel, there is a certain amount of excess air that is not used in the
combustion process that is then released into the stack and out to the atmosphere. This excess air
is being heated, but is not being used by the boiler, which reduces the efficiency of the boiler.
We performed a combustion analysis on your boiler and found your boiler to be operating at
9.5% excess air. Ideally, boilers such as yours should operate close to 4% excess air. We also
found the combustion efficiency of the boiler to be 73.9%. By having your boiler tuned to 4%
excess air, the efficiency of the boiler will increase to 80.8% and save 835 MMBtu annually.
By finding the current and proposed efficiencies of the boiler, with the annual energy output of
the boiler, we found the annual energy savings and the annual cost savings.
Proposal
We recommend that you have a boiler specialist tune
your boiler to produce 4% excess air to increase
combustion efficiency. The annual savings will be
$9,239 with an implementation cost of $350. The
savings will pay for the implementation cost in 0.04
years.
See the following page for more detailed
calculations.
Source: www.parkerboiler.com
Boiler Tune
Data Collected
Stack Temperature
Room Temperature
Excess Air
Current Boiler Efficiency (η c )
Equations
537.0
63.7 °F
9.5 %
73.9 %
Eq. 1) Annual Boiler Output (U )
°F
Eq. 2) Annual Energy Savings (E S )
Incremental Energy Data
Incremental Natural Gas Cost (E C )
$11.06 $/MMBtu
Eq. 3) Cost Savings (CS )
Assumptions
Annual Operating Hours (O )
Boiler Rating (H )
2,920 hrs/yr
3.35 MMbtu/hr
Eq. 4) Implementation Costs (IC )
Energy Savings Summary
Proposed Boiler Efficiency (η p )
Annual Boiler Output (U )
Annual Energy Savings (E S )
(Rf. 1)
80.8 %
9,782.0 MMBtu (Eq. 1)
835.3 MMbtu (Eq. 2)
Implementation Costs Summary
Number of Boilers to Tune(B )
Labor Cost per Boiler (L )
1
$350
Economic Results
Cost Savings (CS )
Implementation Costs (IC )
Payback (PB )
$9,239
$350
0.04 yrs
(Eq. 3)
(Eq. 4)
References
Rf. 1) This was calculated using SteamMaster. The table can be found in Appendix __