EVALUATION OF THE FEASIBILITY OF A WATER RECIRCULATION SYSTEM

FOR THE RANGEN AQUACULTURE RESEARCH FACILITY.

Brockway Engineering, P.L.L.C.

November 7, 1995

Introduction

The Rangen Aquaculture Research facility is located northeast of Hagerman,

Idaho. Water for the facility is drawn from Curren tunnel, a spring issuing from the

north face of the Snake River canyon. Three other water users also withdraw water

from the tunnel under water rights which are senior to those of Rangen, Inc. Because

G the rights of Rangen, Inc. are junior to the others, the spring is an unreliable source: ~ ~"it:>1\ en\-''

~ ~f=~sh raceways frequently go unused for lack of water. One option to acquire

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v17i~~; additional water is to divert water allocated under the senior water rights, use it in the

\- , OCe-t v ..-; 'l . t.'O"\iov'.l- r e~uaculture facility, and return the flow by pumping back to the Curren tunnel, "J(?V ..,,,;._,\.3-\de,- i,.)h'i:)I .

9 _ _ ':,,e. cun'}r thereby having no impact on the water rights of the other users. The purpose of this ~~,~,

s. ~ study is to evaluate the feasibility of such a recirculation system.

System layout

A diagram of the Rangen facility is shown in Figure l. Water is diverted at the

tunne1 via a concrete headbox and pipe, flows through the facility including t\~ief~oFILMEl

4D1v-,. '. .$e._ J cop1e.5 +,. ,;"'°' L1u.K..e.. UtC U 3 1996 ? Ts -1 i.. ;r r· P os z.1 7o;,.,,f -1 ">

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,~ ~ of ?.i\:~wlys, and returns to a ditch which eventually flows into Billingsley Creek. It

~~n ~;. 01\\is proposed to locate a pumping facility near the point where the ditch crosses the

~~~ at the downstream end of the last raceway. This facility would consist of a

~)<>'t,~concretc pump bay, a vertical turbine pump, a flow regulation valve, and a flow

~ ,..tA~ · measurement device.

The return-flow pipe would be buried in a trench along_ the road as shown in

-~f:,<\te,P~' Figure 1. Two possible paths for the pipe are shown: 1) .following the Curren tunnel ..,..,.iOe#',~e;;~ nL ~ ~~ ~~ess road, or 2) followin~ the main road to the toe of the canyon face and going

-~- directly up to the tunnel. Both routes are approximately 2600 feet in length. The first ~!,T

route is less steep, but it would be difficult to dig a trench for the pipe since the

ground contains much rock. The second route would not require a trench from the toe

of the face to the headbox, but placement of a large pipe would be more difficult. In

either case, the return-flow pipe would be anchored to the top of the concrete

headbox.

Water rights ""9<

~ ~s..;:: dt::Dln addition to water rights for Rangen, Inc., three other users withdraw water ~l~c,11"\_

~'( ,f"0

'"' under several rights with priority dates ranging from 1884 to 1908. The irrigation and -~ ,.;rse--'3> . -~ domestic Rangen rights also have early priority dates, but all of Rangen's fish

propagation rights have dates much later than these. The water rights from Curren

tunnel are listed and described in Table 1.

M ,r .. :r·,_,o-e:1 l ,. __ .,q ·JI MEO Ur:C lJ 3 1996

3

Table 1. Water users and water rights from the Curren tunnel

Water user Description of rights Total rate (cfs)

Crandelmier 5 rights for irrigation and stockwater 8.91

Musser 1 right for irrigation and stockwater 4.10

Candy 2 irrigation rights 0.72

Rangen, Inc. 2 rights for irrigation and domestic 0.14

Rangen, Inc. 2 rights for fish propagation 76.0

The total diversion from the tunnel for irrigation and stockwater uses is 13.94 cfs.

Under the proposal examined in this study, this :imount (approximately 14 cfs or 6283

gpm) would be diverted from Curren tunnel. used in the aquaculture facility, and

pumped back to the headbox, thereby having no impact on downstream water users

when the system is in equilibrium. During startup, downstream users could

experience momentary fluctuations in flow as the sytem fills.

The Idaho Department of Water Resources (IDWR) has measured the discharge in

Curren tunnel for the past two years. These discharges are shown in Figure 2.

Minimum flow for the 1993-1995 period was 2.99.cfs in the spring of 1995. The

maximum recorded flow was 20.27 cfs in the fall of 1993.

Preliminary selection of pump

The elevation of the Curren tunnel is approximately 3138 feet1• The elevation of

the ditch at the proposed location of the pumping plant was estimated from a USGS

7 .5-minute quadrangle and found to be approximately 3053 feet. The elevation head

1Covington. H. R. and J. N. Weaver, "Geologic map and profiles of the north wan of the Snake River canyon," USGS publication, 1989

MICROFfLMED DEC O 3 1996

is therefore equal to 86 feet. The pump must be designed to pump 14 cfs against the

total dynamic head (TDH), which equals the elevation head plus the velocity head

plus all head losses in the system.

4

System curves were developed and are shown in Figure 3 for a range of pipe sizes

from 20 inches to 30 inches. The design flow will be 14 cfs, which is the maximum

flow that will be returned to the headbox. However, the ac_tual flow may vary,

depending on the discharge of the Curren tunnel. A pump which delivers a range of

flow from 10 cfs to 14 cfs (4488 gpm to 6283 gpm) against a sufficient TDH the

while maintaining reasonable efficiency is the Ingersoll-Dresser 18NKH. The pump

curves for this unit are shown in Figure 4.

This pump with a 250-horsepower motor and a to-foot column will cost

approximately 521,750 installed, as quoted by Layne Pump of Twin Falls, Idaho.

Selection of pipe size

The cost of pumping is directly related to the TDH which must be overcome. For

a given flow, a larger pipe results in lower water velocity and less head loss due to

friction, and therefore less pumping cost. However, larger pipe costs more. The

optimal pipe size may be found by expressing the tradeoff between pipe cost and

pumping cost in economic terms. For a range of p1pe sizes, the pumping cost per year

was found assuming an average electricity cost of 5.035 per kilowatt-hour. This

average price considers the monthly demand charge, which is based on the power

rating of the pump. and the usage charge per kilowatt-hour. Prices for steel pipe and

installation were quoted by Farrnore Co. of Jerome, Idaho and are given in Table 2.

rvliCFfOFtLMED DEC O 3 1996

Table 2. Cost of steel pipe.

Pipe diameter

20"

24"

26"

36"

Cost per foot

$16.50

$20.50

$23.50

$47.00

It was assumed that the same pump is appropriate over the range of pipe sizes

examined, so that the cost of the motor and pump does not vary with pipe size. A

comparison of the system curves in Figure 3 with the pump curves in Figure 4

suggests that this is a reasonable assumption. It was also assumed that the cost of

excavation and pipe installation does not vary with pipe size.

5

Because the yearly electricity cost is an arnonized cost, the present value was

calculated assuming a project life of 20 years with a minimum acceptable rate of

return of 10%. This amount was then added to the cost of the pipe, which is already a

present value, to yield a total present value (see Figure 5). The pipe size which

minimizes the total present value 26 inches. A very large pipe is selected by this

procedure because when pumping continuously, the present value calculation is very

sensitive to pumping cost, which is a function of head loss and thus the size of the

pipe. If a 24-inch pipe is chosen rather than a 26-inch, the initial cost of the pipe

would decrease to $53,300 from $61,100 but the annual pumping cost would increase

to $46,500 from $45,300. Given than this is a relatively small increase in pumping

cost, and because a 24-inch pipe is easier to handle and may be more readily

available, it may be a better choice.

MIUHrJ~fLMED DEC O 3 1996

6

Allowance for system down time

Water recirculated by the pumping plant would be used for fish propagation.

Raceways require continuous replenishment with fresh water. Any occurrence which

interrupts this flow of water would be devastating to the fish in the raceways and

would result in a significant monetary loss. Interruption of the flow could be caused

by a power outage, a malfunction of the pump or motor, or a break in the return-flow

pipe. A pipe break is unlikely unless the pipe were defective or a weld was

improperly performed. However, the first two scenarios are not only probable but a

certainty if the pump is run continuously. As protection, a redundant system could be

built (two pumps of equal size) and a 440-volt, 3-phase generator could be installed

for use during power outages. Neither of these has been included in the cost estimate

for this study.

Cost estimation

Initial cost estimates for the components of the system and installation are

presented in Table 3. Excavation costs assume a 3-foot wide by 4-foot deep trench

for the pipeline. The pipeline price was quoted by Farmore Co. in Jerome, Idaho for

steel pipe with a wall thickness of 0.281". Installation of the pipeline involves

placement of the pipe and welding of the sections, both of which could be performed

by Farmore. Prices for the pump and motor and the electrical panel were quoted by

Layne Pump of Twin Falls, Idaho and include installation. A flow meter would be

required on the pipeline to measure the return flow to Curren tunnel. An in-pipe

impeller-type meter may be obtained for approximately $900 including installation

from Farm Irrigation systems of Twin Falls, Idaho. The flow should also be

measured in the ditch at the end of the last raceway to ensure that water is ,P.Ot. U( ., . LM IVllvn Jfl ED

[lEC O 3 1996

7

deprived of downstream users who have senior water rights. This cost is not included

in the estimate.

The motor requires a 440-volt, 3-phase supply of electricity. According to Mr.

Greg Evans ofldaho Power, the nearest 440-volt tap is approximately 1050 feet from

the pumping plant location. The cost to tap this line and supply power to the pump

house would be approximately $1875 plus $7.00 per foot, ~or a total of $9,267. Idaho

Power gives a $30 per horsepower discount for large users, which would bring the

cost down to $1767 for a 250 horsepower pump. However, Mr. Evans cautioned that

this discount may not be available next year due to changes in the regulatory

environment of utilities.

Including other costs for concrete, a pre-fabricated pump house, miscellaneous

metal fabrication for an expansion fitting and other incidental work, plus a 10%

margin for unexpected costs, the total initial cost for the system installation is

estimated to be $116,300.

Annual pumping costs were estimated to be $0.035 per kilowatt-hour on average,

which includes both demand and usage costs as discussed previously. Assuming 14

cfs (6283 gpm) were pumped continuously, the annual pumping cost would be

$45,300 with a 26-inch pipe and $46,500 with a 24-inch pipe. One option to reduce

pumping cost is to operate the recirculation system only during the irrigation season

when the other water users were withdrawing significant flow. With a 180-day

growing season from April 15 to October 15, the annual pumping cost would be

$22,300 with a 26-inch pipe and $22,900 with a 24-inch pipe.

Conclusions

The analysis of the proposed recirulation system for Rangen, Inc. shows that it is

a feasible solution with significant annual cost. Even though the arrangement may be

MICROPILMED DEC O 3 1996

8

feasible, a proposition such as this would require the approval of each of the involved

water users with senior rights and of the Idaho Department of Water Resources

(IDWR).

MICFIOFf LMEtD DECO 3 1996

s '. 0 0 m ("") .:u Q 0 CJ.) '"'Ill - -· c.o r to s:: O> m

0

Table 3. Esrimate of inilial cost.

Item

Excavation

Pipeline

Pipeline installation

Pump & motor

Electrical panel

Panel installation

Power supply

Flow meter

Check valve

BullerfJy valve

Pump bay & pad

Pump house

Metal fabrication

Descriplion

1200 cu yds @ $5/yd

2600 ft, 26" @ $23.50/ft

Placement & welding

250 Hp, 6200 gpm pump, installed

All options

Installalion by qualified electrical contracror

440-voll, 3-phase tap, I 050-ft run, minus credit

Grainland impeller w/totalizer, installed

Needed 10 prevenl hackflow afler syslem shutdown

Needed to regulate the flow rate

5 cu yd concrele @ $200 I yd in place

Pre-fob metal pump house 8'x8'

Pipe expansion, misc. brackets & fillings

SUBTOTAL

I 0% Contingency

TOTAL INITIAL COST

Cost Vendor

$6,000 Loosli Excavating

$61,IO0 Farmore

$5,200 Farmore

$21,750 Layne Pump

$5,000 Layne Pump

$1,000 Shotwell

$1,767 Idaho Power

$900 Farm Irrigation Systems

$!000 Farmore

$!000 Farmore

$1,000 ·. Triple-C or equivalent

$1,500 Petersen Brothers

$500 Langdon or equivalent

$107,717

$10,572

$118,289

- - - - -

\

t,,J ' Pumping plant location

Proposed pipeline cl route #l >f>_.. 1- 'f' r:.l

~ ry \bilnlP\

Proposed pipeline route #2

Curren tunnel

Figure 1. An aerial photo of the Rangen, Inc. facility with the proposed layout of the water recirculation system superimposed. The locations of the pumping plant and pipeline are shown.

MICR()FILMED DEC O 3 1996

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25.00

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ll/15 11-30-94 1-30-95 4-1-95 6-1-95 8-1-95

Brockway Engineering, P.L.L.C. 11-12-95 AVGFLO.XLC Page 1 of 1

CGB 11-12-95

Figure 3. System curves for several pipe diameters

120.00

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Figure 4. Pump curves for the Ingersoll-Dresser I 8NKH

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$600,000

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CGB 11-12-95

Figure 5. Pipe size selection by minimizing the present value of total cost

Total P.V

---- - ,------,.·- - --,.---- - ,------

· Pump initial cost

18 22 26 30 34

Pipe diameter (inches)

38

MICRClFILMED PlPfiitLG~ lg~JS3 of 4