Cotton Farm Bore Pump

Overview

A Queensland-based farm specialising in summer and winter crops faced rising energy costs due to inefficiencies in its water pumping system. To address this, Saturn Engineering Group conducted a comprehensive Type 3 Energy Audit on one of its key bore pumps, responsible for irrigating over 600 acres and filling a large storage dam. The audit revealed significant opportunities for reducing energy consumption through maintenance and renewable energy solutions.

Challenge

The farm’s bore pump consumed over 121,000 kWh in a single year, with operational costs exceeding $47,000 under the existing electricity tariff. Despite being appropriately configured, the pump’s efficiency was limited to 58.8%, primarily due to wear and tear and potential water recirculation issues caused by a deteriorated bore column. These inefficiencies not only drove up energy costs but also contributed to increased carbon emissions

Proposed Solutions

The audit identified two key Energy Management Opportunities (EMOs):
Name Pump and Bore Maintenance Installation of a 30kW Solar System
Estimated Cost
$30,000
$37,726
Predicted Savings
28,173 kWh annually (23% reduction)
23,456 kWh annually (19% reduction)
Additional Benefits
Enhanced pump efficiency and lower demand charges.
Annual feed-in tariff revenue of $5,254.59.
Financial Impact
Annual energy costs reduced to approximately $40,700, a 13.5% saving.
Combined annual operating costs reduced to approximately $37,000.

Implementation

The maintenance plan included inspecting and repairing the bore pump, casing, and screens, along with a capacity test to ensure sustainable water flow rates. For solar integration, a 30kW ground-mounted system was recommended, maximizing energy savings which increasing the number of years consumption is below 100MWh threshold between Ergon Energy SAC Small and Sac Large Tariffs. Generating an extra revenue stream through solar feed-in Tariffs.

Results

Conclusion

By implementing these measures, the farm significantly improved its irrigation system’s energy efficiency. Maintenance restored optimal pump performance, while the solar installation reduced grid dependency and provided additional revenue. This case highlights how targeted energy management and renewable energy solutions can drive sustainability and reduce costs in agriculture.

Key Takeaway

This case demonstrates the importance of regular system maintenance and renewable energy investments in reducing operational costs and environmental impact. Saturn Engineering Group remains committed to supporting farms with tailored energy solutions for long-term success.