This page contains answers to common questions handled by our support staff, along with some tips and tricks that we have found useful and presented here as questions. *1

*1. It needs to be recognized that in the world of printed documents that some information is useful for decades other information may be obsolete by the time it is printed.  This is especially true of information relative to regulations.  If you are dealing with regulations it is important to check at County, State and Federal levels to be sure you have all the current requirements.   

Why should I consider a manure system?

1. As herds get larger, the problem - manure handling - cannot be ignored or solved by throwing more labor at it.

2. You also will find neighbors with environmental concerns may dictate the nature of your required system.

3. The EPA, Department of Natural Resources, or other agencies, may suddenly have and impact on your management practices.

Non-Point Pollution is widespread pollution commonly attributed to agriculture caused by application of fertilizers, over application or misapplication of manure, or general abuse of livestock or crop environmental issues.

     A.  States are developing laws that will require storage of manure with controlled spread times.

     B.  Other considerations are being given to controlling application rate to protect the environment from over applying animal wastes.  Soil testing and recorded application rates may be needed to protect yourself.  There is work on 300 units of phosphorus in soil as the maximum allowable - then no more fertilizer (manure or commercial) would be allowed, 100 units are needed to grow a good crop.  With such a standard and accepted management practices, a farmer would have protection against suits, for ground water contamination or stream and lake growth caused by high nutrient content of water.

4.  A good manure system with barn and yard planning will yield better herd health and better production.  Cows in mud or cows in manure don't maximize returns on investments, and certainly don't assist in the esteem of a dairy operation.  Dairy operations will have to look good and create a good image of their product to the consumer.

5.  In the past 20 years, the primary reason for installing a manure system has been convenience.  But, the benefit of eliminating the chore of daily hauling and spreading over a ten year period adds up to a lot of dollars.  Add that to a $50 - $60 / cow per year gain in nutrients and a manure system decision cannot be ignored.

 

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What is the value of manure?

You will find that from the perspective of sustainable agriculture, or nutrient cost, farmers with liquid manure systems frequently look at their crops showing the results of good nutrient management saying, "There is my profit."  It is recognized that 75 percent of the nutrient value of a crop that is fed to animals, ends up in the manure.  Conventional spreading will return about 30 percent back to the soil, 90 percent return is possible by applying at the proper time and getting the nutrients into the soil.  Valuing manure is not simple.  The N, P, K is generally valued at $60- 100/ per cow per year, but other soil building capabilities of manure exist and are harder to value.  Some practitioners of good soil management feel the soil building elements of manure are just as important as the dollar value of the major nutrients.

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What is the future of manure?

You will find that manure will be processed and recycled in many different ways in years ahead.  It is being done many ways on a number of farms today.  Recycling it back to the soil is the logical first phase.  To do this well, a storage facility is required which allows application at the proper time during the crop year.  Separation and reuse of the bedding is done on some farms.  This basically requires a system with lots of water and the entire barn must be designed around the system.  If a floor system is used 75 percent reuse of liquids can be attained, but 25 percent new water is required for each flush to keep separators working properly.  A flush system has a severe weather limitation and works best in warmer climates.  Refeeding of any of the components requires careful monitoring and must be limited to animals not connected directly to the food chain.

Methane digesters have been a hope for many years.  They are most cost productive when the gas can be used for heat production at the source.  The production of electricity adds appreciably to the cost of a system and requires extensive management and service with limited pay back. The contract withy the utility will determine the feasibility of the system.

Changing energy costs affect nutrient cost; the forward march of technology will produce changes in manure management in the years ahead.  Today, making the best use of your home grown nutrient bank with a reasonably priced storage and distribution system will help insure your competitive position.

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YOUR MANURE SYSTEM   

Should I go with a piston pump or an impeller pump?

This question can be answered by considering these factors.

FACTORS for POSTON PUMP BEST

  1. Distance to storage is less than 150 feet.

  2. Bedding is used @ rate of one bale per ten cows.  Bedding is baled straw o r equivalent of chopped bedding.

  3. Power available is limited (10 hp maximum).

  4. Herd size up to 300 cows range.

  5. Farmer operated system, or dependable help.

FACTORS for IMPELLER PUMP BEST

  1. Storage is above ground or elevated above barn.

  2. Distance to pump exceeds 150 feet.

  3. Minimum bedding planned or needed.

  4. Bedding must be chopped or equivalent chopped straw, etc.

  5. Three phase power available.

  6. Flush system being considered.

  7. Farm has hired labor doing chores and hired hands change frequently.

  8. Milking parlor and free stall operation.

  9. System requires mixing or blending before transfer.

If a piston pump is to be used, select one that will pump water as well as manure.  The hollow piston type pump will pump anything that should be pushed into a pipeline.

Care must be taken to control the material fed to the pump.  There are limits to the amount of bedding that can be added to manure and there are limits to what a pump will handle.  This variable  is highly dependent on pipe length.

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What is the design and installation planning code?

PVC PIPE

Use SDR 35 pipe or heavier.  Inspect pipe for smooth inner surface. 

NOTE:  SDR stands for Standard Diameter Ratio and SDR35 means the diameter is 35 times the thickness of the pipe wall.  Review the specifications required by the regulatory agencies in your area.  While SDR 35 pipe is classed as a free flow type of pipe it has been used for pump fed pipe lines for decades.  Pressure rated pipes will rate a schedule 40,80 etc., and are typically water transfer pipe.

PUMPING DISTANCES

Follow the Pipe Length Chart for system satisfaction.  Remember, these figures are maximum guidelines. Pumping to these maximum distances will require tighter management of the system than if the system can be installed with a shorter pipe.  Systems with pipelines of 100 feet or less have consistently better performance, require less power, last longer and have fewer problems than systems with longer pipelines.  In addition, management parameters can be stretched to allow you to do more with the system.  To understand this, consider the problems which would occur with a hay baler with a 200 foot chamber.  Just because a particular manufacturer claims they have a pump that can pump longer distances than another brand does not mean they have a better pump.  All of the significant brands use the same motors and the same pipe.  If you want to pump faster or push more bedding farther, it takes more power. If you pump at the upper limit of bedding, you can reach a point where the required pressure exceeds the rating of the pipe.  Nobody wants to experience a pipe that blows up.  If heavily bedded material from a calf pen or silo top must be pumped, leave it in the gutter overnight to get more manure into it and then add enough water so the material will not pack.  REMEMBER, bedding under pressure absorbs more water.  When it comes out of the pipe it will look like a fiberboard log.  When it went in, it looked fairly sloppy.  The best advice is don't run questionable material through the pump.  A few wheel barrel loads or skid steer buckets of calf pen manure easily be kept out of a system.

If you find a manufacturer who rates their pumps with a shorter pipeline than others, it can mean they have higher standards of what they expect in terms of performance and longevity and NO TROUBLE.

ELBOWS IN A SYSTEM

A 22.5 degree elbow in the pipe is at least equivalent to 10 feet of pipe when close to the pump and 25 feet when on the end of the line.  If a plug of calf pen manure comes sliding along, multiply this factor by an additional 5 or more, depending on the plug.  DO NOT use a single section 45 degree elbow in a manure pipeline.

PUMPING UPHILL

Pumping uphill will require more power.  Shorten the recommended distances by a percentage equivalent to the rise in the line in feet.  Pumping uphill 10 feet should shorten the pipe length rating by 30 percent minimum.  Serious consideration should be given to locating the pit or lagoon where it is not necessary to pump uphill and protect the system from back flow.

PIPE INSTALLATION

Pipes need to be installed with a minimum a uniform grade angle of 2 percent, 2 feet per 100 feet or more.  Do not create low spots in the pipeline.  Low spots become settling points for sand, gravel, and lime and are the point of trouble when lines plug.  The uniform slope provides successful washing of a line if non-organic materials (sand, gravel, lime, etc.) build-up in the pipeline.  Our line cleaning experience has taught us that service  options are a need, not just an option.  If a problem should occur in a system years later, the system is designed to solve that situation as quickly as possible -- with the least time and service necessary while keeping the pipeline intact.  Install and bed the pipe as per pipe manufacturers instructions.  See your pump Installation Manual.

BACK FLOW PROTECTION - PUMP PROVISION

All systems require a protective device at the pump in the form of a pipe mounted knife valve or an internal valve in the pump which closes when the service is necessary to restrict uncontrolled blow back from the line whether caused by liquid at a higher level or stored energy in the line in the form of gas.  If the liquid level in the storage is above floor level at the pump, uncontrolled flow may result if the pipe is open to the pit.  Even if the level of liquid in storage is lower than the pump, an entire pipeful may flow back out through the pump before the gas pressure in the line is released,  This will occur where a pipe is plugged on the storage end and is not remedied within a day or two.  As the manure begins producing methane and other gases, the gas is stored in the line under pressure until one end or the other allows the pressure to escape.  With the cylinder and piston in place, backflow through the pump will not occur.  Removal of the piston and cylinder will allow this pressure to be discharged up through the pump hopper.  This may occur during the removal process or can happen after the cylinder and piston are removed and work begins to unplug the pipe and disruption of a secondary plug near the pump occurs.  (CONSULT OPERATOR'S MANUAL FOR CYLINDER REMOVAL PROCEDURE.)

BACK FLOW PROTECTION - FLAPPER VALVE

If there is a slurry in the pit or tank and it is necessary to control the back flow of slurry into the pipe during service to the pump or failure of the pipe, a flapper valve shutoff is required at the storage end of the pipe,  Remember that service to the pump may be required at the bottom of the pump, 7 feet lower than floor level or service to a pipeline which is almost always at a level lower than the bottom of the storage.  The new N-TECH flapper is unique in that it will not only automatically close, but it allows for the closing of the flapper valve manually.  It also allows inserting a cutoff in front of the flapper to make it possible to remove the flapper door and service the pipe while the liquid level is above the pipe level.  Most of the time it is difficult to get the storage emptied below the pipe level.  The new N-TECH flapper allows isolating the pipe with up to 3 feet of liquid in the pit.  Every liquid system must have a flapper on the end of the pipe.  Failure to do this makes service to the pump or pipe a risky job.

BACK FLOW PROTECTION - KNIFE VALVE

In the event that the storage level of liquid is to be above pump floor level an in-line Knife Valve is required.  This valve can be used in any system for positive shutoff of the line if it is located within a few feet of the pump.  When used as protection against back flow from elevated storage, this valve with a ground level control is installed as close to the end of the pipe as possible.  The N-TECH knife valve is equipped with a lever control for normal operation and a heavy duty driver which is an assist in closing and re-opening the valve.  We've found that when you need to close a knife valve, you don't have time to look for a big sledge hammer to pound on a valve that hasn't moved in 10 years. Thus the Driver is part of the valve.  This valve is also available with a clean out port behind the valve blade, making use of the usual ideal location of this valve to be able to service the end of the pipe.

SYSTEM PROTECTION DEVICES

All systems should be protected with the proper devices to fit the system design.

  1. If the pumping mechanism should be jammed or damaged to prevent proper operation, back flow could occur if the pipe is not equipped with a flapper valve on the storage end.

  2. If the flapper valve fails to close due to damage or material build-up at the pipe end or any other reason, a second cutoff is essential.

  3. The in line Knife Valve will provide positive shutoff of any back flow of manure when needed and is required if the storage level exceeds the level of the top of the pump hopper.

PUMP INSTALLATION LEVEL

Do not install the pump so that the gearbox and motor are below floor level or at a level which might be flooded at any time.  Damage to the gearbox and motor can occur, as well as possible electrical shock from submerged wiring.  If you have an installation that requires extra depth, ask your dealer about an extension kit.  N-TECH provides a simple yoke extension that allows an extra 1 1/2 feet in depth and 2 feet of hopper length.

SERVICE PORTS

In order to adequately provide service to a pipeline, access to the pipe is needed at 100 foot intervals.  This is due to the fact that high pressure washers working in the types of material that is  usually found in manure system pipelines start losing their penetrating force beyond 100 feet and also the fact that 80 percent of pipeline problems are on the pit end of the pipeline.  As you can then understand, a system using 150 feet to 200 feet or more of pipe with no other access to the pipe than through the pump becomes a lengthy service job in January.  Placing the cleaning and flush port on the line , flush out gravel, or enter the line with a high pressure line cleaning device to unplug a pipe line, with a 100 foot head start.  This is also a device that can be added to any existing system.  This type of service port is a standard feature available on the N-TECH Knife Valve.

FLAPPER VALVE INSTALLATION

In a liquid system, the bottom of the pipeline or the level of the flapper device in the pit needs to be 18 to 24 inches off the pit bottom.  The pipe needs to enter the pit through the sidewall to eliminate the need for elbows as is often done when bringing the pipe up through the bottom.  This practice is also consistent with the most important factor in system design.  KEEP THE PIPE AS SHORT AND AS STRAIGHT AS POSSIBLE.  In the event the pit must be emptied shortly before freeze-up, leave enough in the pit to keep the valve covered with slurry.

STACKING SLAB - PLUG BUSTER

In a stacking slab system, the pipe needs to come up through the slab.  If this can be dine without an elbow, do so.  If an elbow is needed, do not exceed 22.5 degrees and keep the elbow as close to the surface as possible.  An N-TECH plug buster attachment on the end of the pipe will deflect the plug upward and help prevent the plug which can resemble a 12 inch log, from sliding along the slab until it encounters enough resistance to STOP, thus plugging the line.  This device also has a provision to allow inserting a length of pipe into the plug buster to provide a higher discharge so manure can be pumped directly into a spreader during the summer.  Caution:  The pipeline may need protection from freezing in some areas.  Two to four inches of Styrofoam four feet wide can help protect from freezing.  The discharge must have sufficient cover for winter.  A 20-30 diameter 3-4' deep foot pile is needed before freeze-up.  10 to 20 bales of hay or straw broken and spread over the pipe or a foot of old silage will protect a pipe until it covers itself.

PUMP VOLUME

While a piston pump is affected by the type of material that is to be pumped, it is a positive displacement device that pumps a specific amount each stroke.  Unless the pump is worn from years of use, or is limited by the lack of the material to feed into the piston (dryer materials or heavy bedding) the pump will pump a consistent volume.  Equipped wit a 10 hp motor and pumping material between high liquids 12-15 percent solids on the maximum end, a hundred gallons per minute is expected performance.  This will mean emptying the hopper in 4 minutes.  This volume will usually sustain a gutter cleaner moving at up to 24 feet per minute from a tie stall  dairy barn with once a day cleaning.  An average size skid steer loader equipped with a bucket or scraping device will usually match the volume of the pump if scraping is done daily while the pump is running.  Again, keeping the pipeline shorter will allow more pump speed and faster pumping.  Higher volumes can be acquired by adapting larger motors up to 20 hp 3 phase or a twin 10 hp single phase arrangement.  This extra power should not be planned into a system to increase pipe lengths but to provide higher volume for larger herds.  If even larger volumes are required, two or more pumps may be required.

GAS PRODUCTION

It must be remembered that all manure systems produce gases.  Any pipe or pit that contains manure will begin producing gases after a few hours.  Gas production will be greatest after 24 to 48 hours and may continue for 3-4 weeks.  Pits and tanks whether open top or covered, must be managed as "Confined Spaces".  Do not enter without proper precautions.  Specific systems must be equipped with warnings which relate to correct procedures for servicing these systems.

YEARLY MAINTENANCE

Annually, or whenever a storage pit is emptied, the level needs to be dropped low enough to see the end of the pipe.  If solids are settling off the end of the pipe, they must be removed.  It is solids off the end of the pipe that slowly accumulate to where the pile in front of the pipe begins backing up into the pipe to create a plug in the pipe, or become an obstruction to a wad sliding out of the pipe.  It is our observation that most pipes plug in this manner.  A good agitation job, with flow directed at the end of the pipe, will correct this condition and if done every time the pit or storage is emptied, will prevent many potential problems in a pipeline.  Most of the time manure system problems are pipeline problems not pump problems.

COLD HOUSING

Cold weather will yield frozen manure during the coldest weather in many of the northern areas of the nation.  Frozen manure does not agitate or pump.  It will pack in a pipe and cause other problems.  Even in slush form, it requires large volumes of water to thaw it out.  When this happens the manure may need to be removed from the barn via an alternative route, whether the manure system includes a piston pump, impeller pump, a gravity flow pipeline, or is designed to flush the system.  A well designed barn will provide for the removal of manure via an alternate route, in the event of this type of problem.

 

 

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Electric Motors

There is considerable difference in the quality of electric motors.  Clues to the quality of a motor can be judged by the brand name, service factor, and prices.  In addition, certain motors seem to do certain jobs better than others.  Heavy starting loads or peaks in the load on a motor often require the use of one motor over another.  Typically a capacitor type farm duty motor will perform well on a piston pump.  The motor must be able to perform well on silo unloaders in cold climates.  Ten hp. motors are usually the motor size of choice.  When the pump does not require the full 10 hp, it will run at a lighter current reading, but will have the torque when it is needed.

If there are special requirements in the design of a machine, the manufacturer undoubtedly will favor a particular motor that has proven to meet the needs of that machine.

If the job requires a heavy starting torque an R.I. motor is frequently chosen.  The user must realize that an R.I. motor requires frequent inspection of the brushes to prevent motor failure.  Annual replacement is normal even with short daily use.

An R.I. motor also exhibits and operating characteristic that must be understood.  This is especially important in that this motor is very expensive and misuse gets very painful in the pocketbook.  The problem comes when the motor is made to run at higher than normal full load current, and then stalled out.  The motor has stored up an internal charge that discharges through the brushes when the motor stalls.  the net result is that the armature is burned out.  When heavy starting or operating loads are encountered the next larger size of motor is usually selected. However, when one hits the 10 hp hurdle and single phase current is the only choice, there is very little that can be done.  Motor manufacturers have been introducing 15 hp. single phase motors for the past few years, however, they are more than twice the price of a 10 hp.  Phase converters are available, but are expensive.  A twin motor arrangement may meet the requirements.

This arrangement will require a double control and sometimes double wiring.  The controls should be set up to prevent simultaneous start up to prevent high demand peaks which can be quite expensive.

In providing overload protection for the motor, the breaker should be sized close to the full load current.  A 42 amp full load motor would be protected by a 45 amp breaker.  this close protection prevents the motor from overheating while the breaker cools during the intermittent load cycle which is created in this type of pulse load.

Consult a reputable electrician or trusted local motor supplier for advice on local application and brands.

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PISTON PUMP SYSTEMS

What factors determine the success of a piston pump system?

The factors that determine this are the barn and livestock conditions that must be built into the system, and the requirements placed on the installation of the pump and pipe line (SEE Pipeline Chart), and the expectation of the owner and whoever will operate the system.  The first two factors present issues that are easily identified.  the last factor can present the real incurables.  To try to accomplish this after the sale can be very frustrating. 

The only real solution to  power is to design a system that will operate within the range of tested operating parameters.  If the system in question includes a manure pump, several items can be adjusted to meet the power factor.

  •   Shorten the pipe line, to save power.
  •   Operate a system with predictable moisture content and keep that moisture level high enough so the material in the line does not start to compress.  A little extra moisture also cuts the stickiness.
  •   Slow the pump down in terms of strokes if it is a piston pump.
  •   Minimize the size of the part doing the work.

- With piston pumps, the piston size and strokes per minute are two factors which determine the power required.  (Also, see the distance charts provided by the pump manufacturer.)  Greater amounts of bedding will require larger pistons.  Attention to minimizing the amount of bedding required in the barn will provide a better system and lower costs for the operation, and allow a smaller piston, thus lowering required power.

-  Grates on gutters, small free stalls in "group" calf pens, chopped bedding, etc.

- The speed of a piston pump is important not only from the direct volume speed relationship, but because of the activity provided in the hopper and cylinder throat, as well as the snap or activity of the piston and cylinder gates.

The installation and start-up of every motor requires both voltage and amperage tests  under full load.  The voltage test assures the proper voltage is available under full load.  A one volt drop in voltage results in a one amp. increase in current flow.  Overloading draws a heavy current, a heavy draw of current usually yields a drop in potential power which requires even higher current and motor failure.  This process becomes destructive very quickly.  The pump should be set up to run at least approximately 10% under the full load current of the motor.  Full load is itemized on the name plate on the motor.  This operating cushion will give some protection if the material going into the pump should become harder to pump. Stiff, sticky manure requires more power than pumping water.  One must realize that when a pipe line has been pushed full of heavy bedded material and then ideal material or near water is fed to the pump, the motor may work even harder than when the heavier material was being pumped.  This is caused because the piston gets a full charge each stroke and the motor must push the heavy material in the line a maximum distance each stroke.

Several factors affect the operation of a pump.  To operate effectively and be trouble free the material to be pumped must be under control.  The physical environment at the pump needs to stay above freezing.

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SAND-IMPELLER PUMPS

Should I use Sand For Bedding and Liquid Manure System?  Impeller Type Pumps

In recent years there has been an increase in the use of sand for bedding in free stalls.  Some have discontinued its use because problems developed that users had not anticipated or in their planning or lack of planning, they could not provide a remedy for the problems.  Before you begin using it or modify your facilities to use it, a full look at all the aspects of its use are necessary.

At N-TECH, we hear some manufacturers making claims their equipment works just fine with sand, but we've encountered sad stories of farmers who have taken that assurance at face value and have found they ran into problems.  Below are a few of the problems you may encounter and provisions you should provide if you use sand.  Also, we relate a few management techniques which can neutralize or prevent some of the problems if followed consistently.

  1. Sand settles out of manure as soon as the consistency reaches a flowable stage.  The more it splashes the faster it will settle.  If you are agitating on one end of a pit, the sand will settle out on the other end of the pit.  Access into a pit needs to be provided so that excess sand can be scooped out when settlings require removal.  This is a need even in reception pits.  It can best be provided by planning a ramp into the end of the pit or at least allowing a removable break in the end wall for a future ramp. (It must be remembered that this will be a "confined space" and requires adequate ventilation before and during entry into the pit.  Testing equipment for proper oxygen and noxious gases must be used before entry and during work in the pit.)

  2. Pipeline discharge ends need to be located so that sand does not pile up in front of the pipe and provide blockage.  Keep the pipe 2 foot or more off the bottom.  Do not end up with low spots in a pipeline or elbows or risers with no provision to flush the pipe on the flat.

  3. Sand will cause a pump to wear faster.  Parts which will wear are the housing, impellers, nozzles, manifolds, and elbows that change the direction of flow.  Life of a pump is dependent upon the mix of sand with the manure and the sharpness of sand particles.  This life may be diminished by a factor of 4 to 1 or more.  Drive train bearings must be pressure lubricated and seals must be maintained or changed regularly to protect bearings.

  4. Agitation within the storage pit should be provided which allows forcefully washing the materials to the pump.  In large or long pits, a sump at the pump a foot to two feet deep, 60 to 100 square feet in area, will allow a more complete pump out cycle.  To assure that sand is picked up during agitation, the rule of 2 ft per second of movement must be reached in all areas of the pit.

  5. When sand ends up in the large storage pit a concrete bottom with exit ramp is needed.  For every 100 yards of sand cycled through the  stalls, expect 100 yards of sand in the storage pit.  The larger the pit is, the more settling should be expected.  Lack of a concrete bottom will require removal by dragline, etc., an expense that can be several thousands of dollars each time.  Dragline use can also damage a liner if clay was used to seal the pit.  If this sand is pumped, it will cause excessive wear on irrigation systems and may accumulate in tankers requiring periodic emptying.  A concrete bottom is a necessary feature of any pit or platform.

  6. Pipelines must be sized to match pump performance.  The velocity of the material through the pipe should be more than six feet per second. With this speed, material that has settled in the pipe will be picked up and removed.  The following figures represent accepted guidelines within the pump industry.

6"    pipe     500 gallons/minute

12" pipe     2100 gallons/minute

 

7. Whenever possible, pipelines and hardware should be kept where they can be disassembled and serviced to correct wear or plugging.  Pipelines must be straight through pipes.  Risers or agitators must be removable to allow cleaning.

 

8.  Pit run gravel may contain rocks that can damage a pump.  While sand is ideal in that it helps prevent cows from slipping on concrete floors and tends to keep the hoof in good shape, small sharp rocks can injure hooves leading to foot rot and other problems.

 

9.  Although sand may be a cheap material and readily available, it must be managed appropriately and you must recognize the other costs associated with its use.  The choice of sand will be a very critical item in the overall success of stall labor, husbandry and manure system management.

  •   Pit run gravel will have rocks which may create a host of problems and will cause pump problems and will be the first material to show up in pits and pipe lines.

  •   Granular structure is the next important factor.  Coarse grainy sharp sand will settle fairly fast and when mixed in a slurry creates an effective cutting fluid in pumps.  Sand of finer texture and flat or smooth grains will stay in suspension better, and will cause less wear to pumps and pipelines.  While a porous material is important so that moisture which ends up in the stall will disappear, it should not churn when a cow steps in it.  It is important to have a base material under the sand fill which will allow water to pass down.  Sand with clay in it usually packs to the point it holds water.

  •   When filling stalls, keep the sand level an inch or so below the curb.  Three to four inches of extra fill in the front of the stall is adequate.  A properly placed brisket board is also important to keep the animal back in the stall, thus keeping manure and liquids out of the stall.

  •   If you have no other alternative to a non-organic bedding material like sand, consider using a fine ag-lime.  It is a material that packs in the stall increasing the amount of time it will stay in the stall.  It has value in the field.  It usually does not contain stones, etc., it is fine enough to stay in suspension as well as can be hoped and some say it helps control the odor.  Use only a finely ground or settlings pond type material.  The use of sand retaining devices may help keep sand in the stall, but you may lose some of the advantages of the sand.

10.  A recent development is the cow mattress which can be installed in free stalls instead of the sand full.  This large heavy duty bag is commonly filled with ground rubber.  Others fill the stall with ground rubber and cover with similar heavy duty bag material.  Rubber mats several inches of thick or water beds are also available each with claimed advantages.  Reports are that cows respond well to this solution.  Various suppliers have varying installation requirements.  Consult a reputable supplier.  Compared to the cost of adding sand regularly to the stalls and the problems associated with pumps and then getting the material to the field, they are an investment worth your consideration.  The cover material will have to be replaced in a period of time, and the fill may have or have additional material added.  Before using, determine what the disposal process is for rubber material that may have to be removed from the stall.

 

11.  In the event sand is planned in a new or existing barn, a fiber/sand separator may need to be planned into the system to remove the sand from the material flow. 

 

WARNING:  Any time you must enter a covered or uncovered pit or tank, realize you are entering a CONFINED SPACE.  The air needs to be tested and monitored to prevent gas problems.  FAILURE TO HEED MAY RESULT IN INJURY OR DEATH.

 

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SAND-Piston Pumps

Should I use sand for bedding and liquid manure system? (Piston Pumps)

In recent years there has been an increase in the use of sand for bedding in free stalls.  Some have discontinued its use because problems developed that users had not anticipated or in their planning or lack of planning, they could not provide a remedy for the problems.  Before you begin using it or modify your facilities to use it, a full look at all the aspects of its use are necessary.

At N-TECH, we hear some manufacturers making claims their equipment works just fine with sand, but we've encountered sad stories of farmers who have taken that assurance at face value and have found they ran into problems.  Below are a few of the problems you may encounter and provisions you should provide if you use sand.  Also, we relate a few management techniques which can neutralize or prevent some of the problems if followed consistently.

  1. Sand settles out of manure as soon as the consistency of the slurry reaches a flowable stage.  The more it splashes the faster it will settle.  If manure containing sand is to be pumped through a pipeline, there are two alternatives:

  •   Keep the material stiff enough to carry the sand in suspension or keep it very liquid and pump it fast enough with an impeller pump so it won't settle in the pipe.

  •   If the stiff route is followed, the material will be too stiff for anything other than a piston pump.  However keep the pipe length to less than half the recommended lengths of the manufacturer.  The stiffer material will pump harder, thus the shorter pipe.  The shorter pipe will allow keeping the manure in a stiffer condition, thus having a better chance to carry the sand out of the pipe, however, operating conditions become very restricted, a single rain or flooding from a waterer, or extra liquid from the parlor can provide a slurry condition where sand will settle in the pipe.  These settlings may create an immediate problem or it may take several months before the pipe becomes plugged.  It must be remembered it is fairly easy to make a slurry a little more sloppy, but once it is too sloppy the sand settles and it is nearly impossible to bring it back to a stiffer range.  If the manure coming off the floor is good and sloppy as it often is from high production herds, the sand will settle.  Once the sand and gravel settle in a pipe, either a solid plug will be required to push the material out of the line, or it needs to be washed with liquids, a flow of six feet per second or more.  That translates into more than 2000 gallons per minute in a 12" pipe.  The piston pump is a 100 gpm pump.  A piston pump cannot flush its own line.

The choice of sand will be a very critical item in the overall success of stall labor, husbandry, and manure system managemen.

Pit run gravel will undoubtedly have rocks which may create a host of problems, will cause pump problems, and will be the first material to show up in pits and pipe lines.

Granular structure is the next important factor.  Coarse grainy sharp sand will settle fairly fast and when mixed in a slurry creates an effective cutting fluid in pumps.  Sand of finer texture and flat or smooth grains, will stay in suspension better and will cause less wear to pumps and pipelines.  While a porous material is important so that moisture which ends up in the stall will disappear, it should not churn when a cow steps in it.  It is important to have a base material under the sand fill which will allow water to pass down.  Sand with clay in it usually packs to the point it holds water.

When filling stalls, keep the sand level an inch or so below the curb,  Three to four inches of extra fill in the front of the stall is adequate.  A properly placed brisket board is also important to keep the animal from laying forward in the stall, thus ending up with manure and liquids in the stall.

  1. Sand can be a comfortable material in the stall and is ideal to provide grit on the floor to prevent slipping by animals.  It is also ideal in providing a degree of wear to the hoof to maintain a healthy hoof.  However, sand which contains pebbles and rocks, especially sharp pebbles, may cause hoof damage which can turn to hoof rot, etc.

  2. A recent development is the cow mattress which can be installed in free stalls instead of the sand full,  This large heavy duty bag is commonly filled with ground rubber.  Others fill the stall with ground rubber and cover with similar heavy duty bag material .  Reports are that cows respond well to this solution.  Various suppliers have varying installation requirements  Consult a reputable supplier.  Compared to the cost of adding sand regularly to the stalls and the problems associated with pumps and then getting the material to the field, they are an alternative investmnet6 you can make in your barn.

  3. If sand is to be used with a piston pump, the pipeline must be kept short, manure consistency must be managed carefully to avoid excess water or sloppy conditions, the pipeline needs a definite slope to the pit and proper sand needs to be selected.

  4. The pumps can pump this manure with sand in it, but the problem will be in the pipeline.  The best advice is do not use piston pumps in barns or systems using sand.

 

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COLLECTION PITS AND AGITATION

 What should I know about collection pits and agitation assist systems?

Long reception pits and vertical pto or electric pumps provide a solution for collecting manure from several scraping points and allowing the material to be transferred to a major storage area some distance from the barn site, up to 1000 feet away or more.  Management of these types of systems is an individual situation and will be dependent upon the material that go into the pit.

Long reception pits typically require agitation at strategic locations to move solids back to the pump where they can be blended into the mass and pumped out of the pit.  Two, three or more agitators is no guarantee that total and complete agitation will occur.  The liquid content will be the biggest factor in determining success of the system.  Straw, sawdust or other organic bedding can typically be compensated for by adding extra moisture.  The rule of thumb is that one pound of bedding will require the addition of one gallon of water. 

 

Non-organic bedding, typically sand, is harder to handle keeping the pit free from build-up.  In fact, it may not be possible to prevent the settling of sand in reception pits or storage, and provisions may have to be made to remove those solids with a load we or backhoe.  The use of pit run sand may introduce rock to the slurry which can damage pumps.  Small rocks may also injure a hoof, leading to hoof rot and problems.

The size of the collection pit determines the agitation system that must be used to move material to the pump.  wider and deeper pits require more agitators than narrower structures.  A Pit that is 10 ft to 12 ft wide may require an agitator at every scrape in point.  A narrower pit four to six feet may only require a line to the far end  to provide backflow in the pit.  Over the top lines and agitators will not require service in the pit and should be used whenever possible.  The pit width and depth should be sized to allow use of a small or medium sized skid steer loader as a last resort remedy to a problem.  This requirement includes the exit ramps.  Slope of the ramp will need to be 1 to 4  or less.  A rough surface on this ramp is necessary.  If a sump is provided at the pump, a ramp out of the sump is needed.  When a smaller collection pit is used, it may be advisable to attach to a larger receiving pit to acquire needed volume.  This pit can be a couple feet deeper than the pit.

To provide all that can be done with a pump, locate remote agitator spouts beyond scrape in ports so that solids and fiber can be moved back to the pump.  Agitators must be located so that each agitator is located within range of another agitator,  This is necessary to allow the agitator stream from one spout to keep sand washed away from the other agitator location.  It will also be necessary to spend sufficient time working on problem areas with the agitators to wash them to the pump.  The pit should be designed with a one to two foot deep sump eight to ten feet square at  the pump to allow a cleaner wash of the long pit floor.

Remember that the coarser sands will settle faster than finer material.  Fine ground or settlings type ag-lime may be used in place of sand.  It is finer than most sand and will not settle quite as fast as sand.  It also lacks pebbles and rocks.  It will not be as abrasive on cattle hooves.  There is a strong economic value to the lime in the manure instead of inert sand.  Again, there are many types of ag lime, choosing a correct material will determine whether it works well.

Material in this type of pit can be loaded into tankers for direct hauling to the field or may as is done in most cased, be pumped to the major storage.  Provision must be made to allow removal of sand from storage by use of a loader or drag line.  Concrete bottoms with ramp allow use of a wheel loader to remove solids.  Tankers need to be rear fill front discharge to provide a flow through path.  In tank agitation is also advised. 

All manure systems have limitations.  Cold barns in colder areas need to be designed to allow removal of frozen solids via a door where they can be loaded into a solids type spreader.

Although sand is cheap, it has other operating costs.  For the longer term trouble free operation of a liquid manure system AVOID SAND.  If you use sand, there are a number of factors which must be done correctly to give you the best chance for success.  See the following for a few of the issues.

Sand for Bedding-Impeller Pumps

Sand for Bedding- Piston Pumps

 

WARNING Instructions must be provided to warn personnel to not enter pit without testing and monitoring the air.  These types of pits are CONFINED SPACES and entry must be avoided.  Failure to heed may result in injury or death.  Consult OSHA Guidelines.  Entry should only be made by peoperly6 trained personnel using appropriate equipment.
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What should I consider as my herd increases?

As herds increase in size, larger storage basins are needed to handle the volume of material that comes from several hundred head of dairy, beef or other livestock.  As the size of the required major storage increases, it is harder to fit into building layouts in terms of initial fit or, later traffic patterns, and more so the esthetics of desired visual and odorous environment.

In systems where a large reception pit or pits are planned into the building layout, the major storage can be moved away from the building site.  With a proper vertical PTO pump driven by tractor or electric, this distance can easily be in the 1000 to 2000 foot range, or further.

Where smaller (10-20 hp) electric pumps, piston or impeller are used, an intermediate storage of 90-120 days capacity can provide a significant sized storage yet not be too large to fit building layouts.  This storage can be concrete lined in the earth storage, above the ground storage tanks, or a form where half the storage is below ground line and half is above ground.  This type of containment can be provided by using poured concrete ,on pre-cast concrete or steel panels.

The pumps to agitate and empty this type of structure are available.  While some limitation in total depth is necessary, the advantage of a moderate sized structure set in the ground with wall protection and agitation and pumping access at any point around the perimeter is a definite operating advantage.  Any time the total storage reaches the million gallon volume, this concept is an excellent choice.  In some cases, it makes sense to pump to more than one major storage facility, planning the storage to fit available acreage for spreading and recycling nutrients.  This concept allows a system of storage faculties preventing the development of a single large structure that is so large that agitation and emptying is a problem.  The ninety day capacity will provide sufficient volume to provide storage through the winter months.  Pumps used to fill tanks or feed irrigation systems can transfer from 50,000 to 150,000 gallons per hour to the major storage where it can be in a strategic location for injection or incorporation at the ideal time for crop and nutrient needs. 

For information on pumps and storage of in ground, above ground, or in ground and above ground types, call N-TECH (715) 537- 9207.

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AUGER SYSTEMS

 What is the proper use of augers and what are some design parameters?

  1. Use of long, uncut bedding must be avoided.

  2. Quantities of chopped straw, sawdust or shavings and other materials without sufficient manure or liquid will not feed into the auger or should not be fed into and auger

  3. The auger incline should not exceed 35 degrees.  Additional angle slows up material flow, requires more power and cuts the range of material the auger will handle.  Excessive angle will prevent the flow of liquids up the tube.  The flow of material into an auger must be controlled.  An auger works best when it runs at about half trough capacity.  When the flighting becomes fully loaded, excessive power required and the load spins with the auger and quits sliding up the trough.

  4. The auger is a single component in the manure transfer system.  Guards and shields must be provided to keep operators or spectators away from the feed or discharge points.

  5. AUGER ARE NOT DESIGNED FOR SOLID OR PEN MANURE OR WATER.

  6. AUGERS ARE FOR HANDLING FREE FLOWING SEMI-SOLID MANURE.

  7. It is best to feed material to the auger from the left hand side of the hopper.  This gets the material into the auger quickly rather than the auger throwing the material across the hopper to reach the side of the auger that pulls material down into the trough.

  8. Observation of N-TECH and competitive units shows a pattern of auger deterioration and troughs being worn out in 3-5 years.  It should be realized that an auger is a low efficiency, high wear, transfer device.  Use of sand will require replacement sooner.

  9. At N-TECH we have avoided installing augers in pits which are supposed to provide several days of storage.  It is our observation that a high percentage of these efforts lead to trouble and will not work unless all bedding is eliminated and adequate liquid is added to provide a free flowing "liquid" slurry which is ideal for a small pump.

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GRAVITY SYSTEMS

How can I operate a gravity system effectively?

While making use of gravity is a simple natural phenomenon, its use in a trouble free manure system must be done carefully.  Remember, a gravity system with 10 feet of elevation difference will yield less than 5 psi pressure.  While high liquid materials will  move freely, various bedding materials can yield surprises in a pipeline, even large diameter pipelines  Most organic bedding materials float in liquids.  Cornstalks, straw sawdust, etc. can fill the top of a pipe allowing the liquid to flow underneath.  If the floating mass can create enough friction against the top of the pipe to hold the maximum liquid level, sometimes several feet of head, the pipe may become blocked when bedding may close the bottom opening.  A slippery pipeline helps prevent this.  Plastic pipe is a better choice than concrete or tile.

To work effectively, this type of system requires a consistently sloppy stream of material.  Outdoor lots where drying and freezing occur create materials that should not be pushed into a gravity system.  Those materials must be loaded and hauled or pushed directly into the storage pit usually over a straight wall.

Gravity systems with too much slope seem to drain the liquids through the pipe while leaving the bedding and solids in the pit or pipeline.  While the receiving pit can have considerable height, the pipe needs proper slope.

It must be expected that production of gases will occur in the pipeline.  With the upward slope to the barn, most of those gases, methane, carbon dioxide, CH4, and others will feed back up to the collection pit.  This process demands ventilation protection and warnings of this hazard.  Also, the pit must be identified as a CONFINED SPACE with appropriate warnings and precautionary service procedures.

Lime, sand and gravel become progressively worse as non-organic bedding material in a gravity system.  These types of materials begin filling the pipeline from the low end back up into the pipe.  Gravity systems require a high liquid content, thus solids can easily settle in the pipeline. 

For hardware to improve the function of a gravity system cal us at (715) 537-9207

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INFORMATION

Do you provide information about vertical electric design and purchase parameters?

Yes! Below is a summary of information that will help you to make important decisions.

Several size Vertical Electric Pumps are available from N-TECH.  They are designed for motor sizes ranging from three to fifty horsepower.  As for intended use, they range from pumping milk room and parlor wastes to handling 100,000 gallon reception pits.

The expected usage ranges from less than an hour per day to 10 - 20 hours per day.  Several factors must be considered in the process of selecting the correct pump for the job.

The following gives a preliminary view of pump selection.

Pump size is first choice:

Pit depth-  6ft -12 ft.  N-TECH pumps are sized in two foot increments.

Volume- Determine the needed volume.

Material- Some pumps are designed to pump basically water, others can handle more solids.  Solids come in many forms.  Fibrous materials may be bedding or feed materials.  Attempting to chop materials in a slurry is generally a non-productive effort.  Cutting knives have a short life and soon become dull at which point chopping ends.  N-TECH pumps are built with a reverse saw tooth inlet to provide a shredding action on anything large enough to not flow directly through the impeller.  It is usually more productive to chop bedding materials before they are used for bedding.  As fibrous materials increase, the most effective solution is to be sure the pump is large enough to handle the type of flow which will prevent clogging of the inlet or piping.  A pound of bedding requires a gallon of water to make it pump able

Power- Is a determining factor, this should be dealt with correctly the first time a decision is made.  Having to up-size a pump because optimistic decisions didn't work can be expensive.  Three phase power, phase converters or PTO power may be needed to do the job.

Duty- Operating conditions affect the size and drive train requirements.  A pump which will run less than an hour per day pumping high liquids can be  a light duty pump.  Pumps tied into flush systems or separators may require 10 to 20 hours of operation per day. This can convert into three to seven thousand hours of operation per year. Appropriate drive trains must be selected to fit this need.  This type of use also requires installation of double pumps so that service will not interrupt the schedule of the system.

Bearings- Marine bearings are very effective on light or medium duty jobs.  And they are easily replaced in split form.  A maintenance task requiring a half hour if done before a complete destruction of the bearing.  Ball bearings in oil filled tubes can provide extended use and are best choice for automatic systems.  Outrigger seals can protect the bearings thus extend the life, however, preventative maintenance to the seals should be provided on a regular schedule to prevent breakdown.  Bearings normally have a high expected life if protected from slurry material.  Seals may be limited to a thousand or two thousand hours, depending on the type of material being pumped, lubrication cycle, etc.  Thus, they need to be replaced regularly to protect the bearings.  In larger operations, a preventative maintenance service contract to provide this type of service is very beneficial and cost effective.

Product list- expected uses to size pump

MODEL

TYPE

USE

DDP

3-5

Use

Vertical Electric 5/10

5-10

Hog operations.

Parlor and wash up water run-off.

Flush water separator.

Liquids less than 5% solids.

Vertical Electric 5/10

(oil filled driveline)

5-10

Separator or flush systems with automatic controls, or systems operating more than 2 hours/day.

Vertical Electric 10/15

10-15

Any of above.

Dairy Operations from free stall floor or barn cleaner.

Limited chopped bedding, extra water added as needed.

Liquids less than 8% solids.

Vertical Electric 10/20

10-20

Same as 10/15 only this unit has oil filled sealed drive shaft.

Needed on flush and separator application or higher lift needed.

Vertical Electric 30/50

20-50

Any of the above and heavier service jobs.

Reception pits to 20' x 40'.

Liquids less than 10% solids.

This pump is available with twin 20 hp motors.
Motor Sizing

When motors are sized to the pump, it must be recognized that opening an agitator while pumping out can require extra amperage.  The motor must be set-up to either put full power into pump out or agitation or handle both functions at once.  Motor amperage can be diminished by changing sheaves to slow pump down, or as is sometimes done to use a smaller diameter agitator nozzle.  Volume is directly associated with required power or amperage.  Raising the pressure will cut volume, thus lower required amperage.  Wiring must be done by a qualified electrician to assure meeting appropriate codes.  Wiring which is a little light or a bit over length can yield low voltage.  Remember a 1 volt drop in voltage will yield a 1 amp increase in amperage.  This easily leads to motor overload.

Required Pump Openings

The minimum size holes required for pumps are indicated below.

Model Hole Size (minimum)
DDP 14 x 16
5/10 17 x 20
10/15 22 x 24
20/50 28 x 48
If a new system is being created, design it with a 3 ft. wide 4 1/2 ft. long hole.  This will allow use of a variety of pumps over the life of the pit.  The opening should be in the middle of the longest wall to minimize agitation distance and allow a circular swirl in the pit.  It needs to be where it allows removal and service of the pump.  The best location is where the most liquids accumulate, usually away from the scrape in port.

Pump ports need covers and barriers to guard openings.  It must be remembered that a barrier is required when the hole is open.  These are field installed and need to be built to withstand any expected load plus additional safety factor.  Holes in pits in areas with freezing temperatures require tight lids.  Cold air flows into pits continuously.  Pits with more than one hole can develop a draft through the pit without lids.  It may be necessary to maintain a minimum of 3 feet of liquid during coldest weather to prevent the pump from freezing.

Ceiling Height

To run the pump up the rail and provide service to the impeller housing above floor level, the normal required ceiling height will be pit depth plus 5 feet.  Sometimes a dormer may need to be built into the roof.  Occasionally the pump is mounted in the hole using a stationary mount bracket and the pump in turn will be lifted out of the hole using a skid steer loader or other device.  This may require less ceiling height.

Pump Out Packages

To connect to transfer piping, it is advised that connecting plumbing be done above floor level.  Avoid creating in the pit installation or service jobs.

WARNING ENTRANCE TO ANY PIT IS A "CONFINED SPACE" ENTRY AND MUST BE DONE ONLY UNDER TEST AND MONITOR OR PROPER VENTILATION PRACTICES.  CONSULT YOUR OSHA REGULATIONS FOR PROPER PROCEDURES.  FAILURE TO HEED CAN RESULT IN DEATH OR INJURY.
Installation in a new pit can be done with a minimum of risk, but still requires confined space procedures.  Once the system is in use, you must expect unsafe air in the pit.

Water Source

A water hydrant should be installed near pump site to allow adding water if and when it is needed.

A frost free unit is advised.

 

Pipe Systems

Four basic pipe systems are used for pumping out of the reception pit.

 

Over the Top

Can be used to fill slurry spreader directly or top fill of storage tank.

  Top to Bottom

Can be used in warm areas or protected building

  Bottom Fill Pack

Designed to protect pipe and valves from freezing

Bottom Connectors

Designed to engage when pump is lowered into lowest position

Special Conditions

If freezing is expected with the bottom fill, leave enough in the pit to completely cover the housing flex tube or connections and valve through the wall.

If bark or chunks of bedding material are used, design the system with up and down or over the top pipe system as it allows some service without lifting the pump.  Piping also remains a full 6" whereas the bottom fill requires stepping down to a 4" to obtain flexibility of the tube.

N-TECH Vertical Electrical pumps are designed with an agitation port which can be used as an alternate pumping outlet for regular use or emergency situations.  A variety of hardware is available for these needs:

  1. The over the top pack is an ideal accessory which can be used to top fill a slurry tank or can be used to pump directly into a slurry tank spreader.

  2. Additional agitation can be obtained in a pit by adding an extra agitation spout to pump back down into the pit on the far side.

The PVC pipe used to pump to the storage facility must be 160 psi rating or greater.  Although the pump will not create pressures in excess of 60 psi, unexpected strains and service operations might someday tax the line for the full pressure rating.  Manure can be pumped to open pit storage or above ground structures.  Do not exceed 40 feet of head.

Reception Pit

The reception pit must be large enough to hold at least one days production of manure, 3-5 days is desirable, and liquids with room for sufficient water to obtain proper final mix.  Calculate the amount of manure produced in a day and double for a minimum size pit.  Multiple sizes can be used for longer accumulation periods.  DO NOT OVER SIZE THE PIT OR AGITATION PROBLEMS WILL RESULT.  Use pump selection table for matching pump to pit size.  When planning a reception pit, use the tables to choose pumps and motors for a system.  Simple combinations of length, width, and depth will produce the volumes shown.  If possible stay in 6-8 feet depth ranges.  Deeper pits are harder to install and harder to service when solids accumulate.

 
When installing a pump in a reception pit, the pump should be in the center of one wall of the pit.  Do not place pump in a corner.  Being in the center of the wall will allow maximum angle of agitation and maximum flow to pump inlet, in addition to a fairly short distance to all points in the pit.  The location also establishes a current flow in the pit keeping a swirling action.  Being in a corner cuts agitation angle to less than 180 degrees, cuts flow to inlet and creates a corner where solids will pile on top of the pump housing.

If a round pit is planned, mount the pump on an outside wall.  This provides best current flow in the tank and prevents a dead area in the tank.

 

 

POWER

Baldor Rl 10-15 HP

When using the Baldor single phase 15 hp Rl motor, one must remember it has a one hour rating at 15 hp.  Longer periods of use will generate internal heat in the motor and burn the windings.  If the motor operates at the amperage required for 10 hp, then it is rated continuous duty.  If electric conditions only allow 10 hp, then a Mini-Shredder (if the manure is over 90 percent liquid) or a piston pump must be used.  Brushed must be replaced at 200- 300 hours.

Roto Phase

An alternative to single phase soft start motor would be to use a Roto-Phase unit and standard 3 phase motors.  The initial cost would be slightly higher, but the Roto-Phase unit would allow conversion of motors on feeding equipment to three phase, resulting in considerable saving over the long run.  In addition, any future repair of motor would be expected to be less.

Twin Motors

Motor drives utilizing the two motors are available.  This combination allows use of standard motors and permits the pump to be run with 20 hp or more.  A special switch is used with these motors providing phased starting and double motor protection.

PTO Drives

Larger jobs may require 20-50 hp electric motors or twin motors as discussed.  Even larger jobs can be done with electric motor/PTO converter or driven directly with a PTO drive.  These drives utilize a 90 degree gearbox mounted on the top of a pump and utilize a 540 or 1000 rpm PTO.  This shaft length is limited to five feet or so tractor location becomes a factor.  If shaft extensions are needed up to 20 foot extensions have been provided to allow keeping the tractor  out of the barn or off the slats.

Electrical Service

Motor starter, switch devices, etc. should be located so that disconnected piping or connections will not direct a flow of liquids at electrical devices.

Sand

The use of electrical pumps in systems allowing sand into the slurry is not recommended.  Normally, a larger pump is required which can provide greater agitation to keep the sand in suspension.  Heavier iron to resist wear is also a consideration for PTO type pumps.

Automatic Controls

Pumps installed with automatic on and off need a secondary off timer to prevent the pump from continued running if the off control fails.  Marine type bearings will run only a few minutes before they begin to melt after liquid level drops below the bearing.  Pumps which start automatically need a visible warning sign which states "THIS UNIT STARTS AUTOMATICALLY WITHOUT WARNING."

Agitation

Reception pits which are not pumped out daily require ventilation before and during agitation. Larger pits especially require ventilation which is directed out of the building.  Operators need to understand that livestock and personnel can be at risk if they occupy a building which has manure storage located under it and agitation is performed without adequate ventilation to prevent gases from rising into the building.  An agitation warning should be posted near the pump to advise personnel of the risk and proper operating procedures.

System Size

On large systems with several hundred animal units, it is advisable to plan a double pump system.  Either pump should be set-up to do the transferring of material and secondly, can do agitation.  In the event of a problem or maintenance on one unit, the other is available to do the job.  This assures always being able to handle wastes while repairing a motor, pump, or other hardware.

Service

PREVENTATIVE MAINTENANCE

Check coupler rings, housing condition, bearings and other components to prevent breakdown.  The marine type bearing is easily changed.  Replacement of shaft, impeller and housing because of a failed bearing is expensive.

Service to pumps must be done above floor level.  Any service that must be done below floor level requires air testing and ventilation before entering the pit and during the stay in the area.  OSHA regulations provide requirements for procedures that must be followed.  Anyone entering the pit should receive proper training before attempting entry into any CONFINED SPACE.  Some of the requirements are:

  •   Entry permit must be completed before entry.

  •   Entry must never be made alone.

  •   Two standby assistants must remain out of the pit or CONFINED SPACE.

  •   A safety harness, safety line, and lifting device must be in place for immediate removal of service person if trouble develops.

  •   The air must be tested before and during entry.

  •   Proper ventilation must be provided or a breathing device must be worn and used.

Designer of the pit should provide a CONFINED SPACE WARNING sign appropriate to the size, location, and other parameters relevant to this need.

Provide LOCK OUT  capability for the controls to provide for safe service to unit when needed.

PIT SIZES    
high liquid

(Hog or equivalent)

 Less Liquid

(Dairy)

 Pipe Length (max.)

(See note below)*
  pit capacity gallons pit capacity gallons  
5/10          
5 hp 360 2700     50 feet
7.5 hp 600 4500 not recommended 100 feet
10 hp 800 6000     150 feet
10/15          
10 hp 1000 7500 800 6,000 100
15 hp 1500 11,250 1200 9,000 150
20 hp 2000 15,000 1500 11,250 200
20/50          
20 hp 2000 10,000 2000 15,000 100
30 hp 4000 30,000 3000 22,500 200
40 hp 6000 45,000 4000 30,000 300
50 hp 8000 60,000 5000 37,500 400
* Consideration of pump size must be given depending upon pipe length.

This is a factor in motor size.

SPECIFICATIONS

PUMP MODEL

HORSE POWER

BEARING TYPE

PIT DEPTHS

MAX PIT SIZE

(W-L)

% liquid

MAX DAILY OPERATION HOURS

DDP

 5, 7.5

MARINE

6,8,10

8 X8

1

 

 

 

 

 

 

Vertical Electric

 

 

 

 

 

5/10

5,7.5

marine

6-10

8 x 10

2

5/10

5,7.5,10

oil filled

6-12

8 x 10

10

10/15

10,15

marine

6-10

10 x 16

2

10/20

10,15,20

oil filled

6-12

10 x 20

10-20'

20/50

20,30,40,50

oil filled

6-12

20 x 40

10-20

 

(or two 10 hp, 2-15 hp, 2-20 hp, 2-25 hp)

 

 

 

 

 

 

Hydraulic Submersible

Req. Hyd

2000 psi

 

 

 

 

8"

10-12 gpm

 

      

10"

12-14 gpm

  

variable

8 x 10

1-2

12"

12-15 gpm

  

variable

10 x 16

1-2

14"

15-20 gpm

  

variable

10 x 20

1-2

Spec

          

Vertical PTO

60-180

  

6-12 ft

40 x 60-180%

cont.

(Standard Mangum)

 

 

60 x 100-92%

 
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I have an "Impeller Transfer Pump."  What are your recommendations?

Impeller pumps work best with plenty of water.  All material must be free flowing to properly blend or mix in the pit.  They are the best alternative when manure to be pumped is of a mixed variety, such as outside lots and free stall combinations.  During periods when outside lots are dry, they can be mixed with slurry manure and water for pumping.  During cold periods, partially frozen manure can be pushed into the reception pit, mixed and pumped.  When the frozen manure to slurry ratio becomes higher than 1:2 it may be necessary to allow manure to thaw in the pit overnight.   One point to remember -- once manure or water becomes frozen, it takes more than a hundred times as many BTU's to change it from solid to a liquid with no change in temperature, as it would to raise the temperature one degree (c) as a liquid.  When the ratio of frozen to unfrozen becomes too high, an alternate method must be provided to handle the frozen manure.  When scraping into the collection pit, add sufficient water to the pit before dumping frozen or dried material into the pit.  Manure must be in 90 percent moisture range or above to pump with an impeller type pump.  Manure directly off a free stall floor is close to 80 percent moisture.  To change from 20 percent solid to 10 percent will require the addition of one gallon of water to every gallon of manure.

The following chart gives data as to the amount of water required to raise the liquid content of varying mixtures.  Poultry manures vary widely and must be handled on individual conditions. Many hog systems may have enough water to be pumped directly.  Use of an Impeller Pump and 6 inch pipe is the best choice for pumping manure containing grit, sand or lime.  The high velocity of material in the pipe keeps the line flushed out.  However, minimizing grit and gravel will maximize the life of the pump.  Excessive amounts of lime and gravel will cause agitation problems in final storage.

A Shredder or Chopper Pump is not a cure-all for a long straw situation.  Long straw or hay is very difficult to cut once it becomes mixed with liquids and manure.  It should not be sold as a method to chop bedding to facilitate removal from storage.  Efforts to promote chopper pumps for this purpose have not proven very successful.  The effectiveness of the chopping device deteriorates in weeks.  It is much easier to chop the bedding when dry with a bedding chopper than to try to accomplish the job in the reception pit.  Shredding, if it must be done, is also done best with lots of water to carry the bedding.

There is no specific point at which manure changes from wet to fluid or fluid to liquid.  Manure with bedding added can be high in moisture, yet remain as dry manure from the standpoint of handling.

A general range of moisture content for manure without bedding would be as follows:

75% - 80%  moisture - stiff, some during taken place for dairy, beef and swine manure.

80% - 85% moisture - fluid or semi-liquid, quick thick and slurry.

85% - 93% moisture - liquid, fairly thin liquid at 90%.

93% - 97% moisture - Irrigation consistency.

 

(Assumed Correct; Mid-west Planning Service Materials)

APPROXIMATE AMOUNTS OF WATER REQUIRED TO INCREASE THE MOISTURE CONTENT OF ANIMAL MANURES

 

Initial

Changed To

 

Moisture

Volume

Moisture

Volume

Gallons

%

Cubic Ft.

Gallons

%

Cubic Ft.

Gallons

Added

84

1

7.5

87

1.23

0.2

1.7

 

 

 

90

1.6

12.0

4.54.5

 

 

 

95

3.10

23.3

15.8

80

1

7.5

85

1.33

10

2.5

 

 

 

90

2.0

15

7.5

 

 

 

95

4.0

30

22.5

75

1

7.5

80

1.25

9.3

1.8