PLUMBING SYSTEMS FOR CROP SPRAYERS

The plumbing systems of agricultural sprayers are usually considered foolproof. Sprayer problems may occur if plumbing and/or modifications are improperly done or maintenance is ignored. Retrofitting, addition of electrical control systems, and replacement of pumps or nozzles require proper knowledge of the plumbing system and the implications of these changes to sprayer performance. Routine maintenance of the plumbing system is essential. 

PUMPS

A major component of the plumbing system is the pump. The characteristics of a particular pump will usually define the plumbing system. Most pumps are categorized as positive displacement or nonpositive displacement pumps.

The positive displacement pump moves a specific volume of liquid with each stroke or revolution. The pump output is proportional to speed and virtually independent of pressure. Examples of positive displacement pumps include piston, roller and diaphragm.

The output of nonpositive pumps varies directly with pump speed and is sensitive to pressure. Typically, the output will decrease dramatically with increasing pressure. An example of a nonpositive pump is a centrifugal pump which has an impeller with curved vanes that rotates at high speeds. The liquid is drawn into the center of the impellers. Then the liquid is dispersed by centrifugal force around the edge of the pump casing and through the outlet.

Characteristics of several pump types are outlined in the table below. Of these types, roller, centrifugal, and piston pumps are the most widely used on agricultural spraying equipment.

PUMPS FOR AGRICULTURAL SPRAYERS.
Pump Type	Pressure Ranges (Bar)	Operating Speeds (rpm)	Flow Rates (L/m)	Displacement Type
Centrifugal	0.4-6	2000-4500	0-480	nonpositive
Diaphragm	3.5-60	200-1200	4-240	semipositive
Piston	28-70	600-1800	20-240	positive
Roller	3.5-21	300-1000	4-180	positive
Turbine	0.4-4.2	600-1200	40-320	nonpositive

An important factor in pump selection is discharge capacity. The pump should have sufficient capacity to supply all the nozzles and other accessories, provide agitation and offset pump wear (20% greater capacity). Use the following to determine pump capacity:

 

Where:
Boom Requirements (L/m) = Number of nozzles x flow discharge per nozzle (L/m).

Agitation Requirements (L/m) = Use guidelines given in section on Agitation.

Self Cleaning Strainer (L/m) = Extra flow needed to clean strainer.

1 (L/m) = Extra flow to assure proper operation of the by-pass valve, and

1.2 = 20% extra capacity for pump wear.

If the output from a pump fails to meet the sprayer nozzle and agitation requirements, the pump should be overhauled or replaced.

 PLUMBING SYSTEM FOR NONPOSITIVE DISPLACEMENT PUMPS

The centrifugal pump is widely used to apply pesticides. One reason for its popularity is the simplicity of the flow control system. The pump is recommended for solutions that require additional mixing (ie. wettable powders) and agitation. Since this is a nonpositive displacement pump, the output can be completely shut off without needing a pressure relief value. The discharge of the system is controlled by a throttling valve or electrical regulating valve. If used for agitation, the spray solution for jet agitation is routed before the flow control valves.

If a combination of manual and electrical control valves are used, proper sequencing of valves is important. Incorrect valve placement can lead to pressure surges and premature failure of the electric regulator or pressure gauges. Proper arrangement will allow the manual throttling valve to regulate major pressure changes while the electric regulating valve can be used to "fine tune" nozzle pressure from the operator's platform.

Following are operational guidelines for using a spraying system with a centrifugal pump:

1. Prime pump with all valves fully open.
2. Close the throttling valve while opening the boom solenoid valves.
3. With the pump running, adjust the throttling valve until the pressure gauge indicates the desired pressure.
4. Check for uniform discharge from the nozzles.

PLUMBING SYSTEM FOR POSITIVE DISPLACEMENT PUMPS

The characteristics of a positive displacement pump require a mechanism to release pressure and prevent damage when all outlets are closed. A spring actuated pressure relief valve insures a safety route to a by- pass line . Use the pressure relief valve (or regulator) to make large pressure adjustments. The pressure relief valve adjusts the flow between the nozzles and the by-pass line back to the tank. An electric regulating valve can be used to "fine tune" the required nozzle pressure.

When positive displacement pumps are used, pressure relief valves designed to handle the system's maximum pressure are needed. As with nonpositive displacement pumps, the sequencing of the valves is very important to avoid performance problems.

Following are operational guidelines for using a spraying system with a roller pump:

1. Fully open the agitation valve, pressure relief valve, and boom electric ball valves (or spray gun).
2. Start the sprayer. Make sure the nozzles have uniform discharge rates. Adjust the pressure relief valve until the pressure shows about 0.5 to1 bar above the desired spraying pressure.
3. Use the electrical regulating valve to "fine tune" the pressure.
4. Shut off the boom valves. If the pressure increases over 0.5 bar, the pressure relief valve should be replaced with a larger capacity valve or the by-pass line may be too small for the excess flow.
5. Check for uniform discharge of nozzles.

 HOSE AND LINES

All hoses and fittings should be constructed with quality materials and sufficient strength to handle liquids under maximum pressure. These hoses and lines should be selected based on composition, construction, and size.

Hoses should be flexible, durable, and resistant to sunlight, oil, chemicals, and general abuse such as twisting and vibration. The outer coatings of the hose should be resistant to chemicals because they may come in contact with the spray solutions. Sunlight-resistant materials increases durability. Two materials that are chemically resistant are ethylene vinyl acetate (EVA) and ethylene propylene dione monomer (EPDM). A special reinforced hose must be used for suction lines to prevent collapsing.

The suction hoses should be airtight, noncollapsible, as short as possible, and as large as the intake port. A collapsed suction hose can restrict flow and "starve" a pump, causing decreased flow and damage to the pump and seals. When spray pressure cannot be maintained, check the suction line for restrictions.

Lines between the pressure gauge and nozzles should be as direct as possible with minimum fittings, throttle valves, and restrictions. These lines should be plumbed to the center of each spray boom . Spray lines and hoses must be of the proper size. The proper size of these lines will depend on the inside diameter of the hose and the flow capacity (l/m) of the line. Sufficient flow velocity is required so that suspended particles will not settle in the lines. If lines are too small, excessive pressure drop will occur and the flow at the nozzle will be insufficient. A flow velocity below 12.5cm per second is recommended. suggested hose sizes for various flow rates are given below.

  Many sprayers are constructed with "wet" booms and are fitted with nozzle assemblies that protrude 1/3 to 1/2 of the diameter of the boom. These nozzle assemblies take the spray solution out of the middle of the boom. The wet boom makes it possible to flush out materials like sand and rust in the bottom of the spray boom. Equip a wet boom with plugs or hose-end caps on the boom ends so they can be easily flushed.  Some pesticides will damage PVC so review the compatibility tables. Stainless steel is the best material and can be fixed with hose-end caps to make flushing and draining convenient.

RECOMMENDED HOSE SIZES FOR VARIOUS FLOW RATES.
	Hose Size Inside Diameter (inch)
Highest Flow Capacity (l/m)	Suction Hose	Discharge Hose
0-4	1/2	1/4
4-12	1/2	3/8
12-24	3/4	1/2
24-48	3/4	5/8
48-100	1	3/4
100-200	1-1/4	1
200-400	1-1/2	1-1/4

AGITATION

The amount of flow required for sufficient agitation depends on the chemical formulation. For example, wettable powders require more agitation than emulsifiable concentrates to keep them in

suspension. Applications that require vigorous agitation may need mechanical agitation such as propellers or paddles on a rotating shaft. For most spraying situations, hydraulic agitation is sufficient.

Hydraulic agitation requires a portion of the flow from the pump to be diverted back to the tank. The amount of flow for agitation will depend on chemical formulation and tank size and shape. As a rule of thumb, use 5 to 10 percent of the tank's capacity for agitation flow. For example, a 1200litre tank should have between 60 and 120 l/m of flow into the tank. After selection of the agitation flow rate, select the correct orifice size required .

The use of siphon caps on the jet agitators can reduce flow requirements by half. The siphon caps increase the flow by venturi action which increases the mixing potential.

 Often, sprayers are plumbed with the agitation coming from the by-pass line. This arrangement does not give the operator control over the amount of flow for agitation. For example, when a large flow is needed by the nozzles, there may be insufficient flow from the by-pass line for adequate agitation. But when the nozzles are shut off, all of the flow is diverted into the by-pass line which causes foaming in the tank.

 TANK AGITATION CAPACITY.

Orifice Size (mm)	Inlet Flow* (l/m)	Outlet Flow* (l/m)
3.13	11	38
3.90	16.4	52.8
4.70	21.2	61.6
6.25	26	78
JET-Spring-Loaded	0-15	2.5 times inlet orifice
*Rates given at 2bar

STRAINERS(KICHUNGI)

Line and nozzle strainers are a very important component of the sprayer's plumbing system. Properly sized and located strainers will prevent plugged nozzles or partially plugged nozzles and the uniformity problems associated with them. The mesh size of a strainer refers to the openings in a screen per linear inch.

For most positive displacement pumps, a suction line strainer between the tank and pump is required. This strainer should have a 30 to 50 mesh screen. A large suction line strainer (12 to 16 mesh) to keep rocks, labels, booklets, etc., out and to protect the pump should be used with a centrifugal pump. The strainer mesh must be larger so the inlet of a centrifugal pump is not restricted. If restricted, a centrifugal pump will create a vacuum within itself, thus starving the pump. A smaller strainer of 50 mesh should be located on the pressure side of centrifugal pump to protect nozzles and the agitation system.

A beneficial addition for sprayers is a self-cleaning line strainer . These strainers have a high velocity flow over the screen which provides a continuous washing. The additional flow required for this washing action is 24 to 32 l/m per strainer. Additional plumbing and a throttling valve are required to control the flow of wash water.

 SELF-CLEANING STRAINER.

Screening should be progressively finer from the tank to the nozzles . The largest mesh screens should be in the filler opening and in the suction line. The screens need to be keyed to the nozzle orifice size. Screen area should be large enough to prevent pump starvation or excessive pressure losses. As a rule of thumb, use at least 1.25square cm of screen area for each l/m of flow in the suction line. Strainers, between pump and nozzles, should have at least 0.625 square cm of screen area for each l/m of flow.

Nozzle screens are very important, since they are the last chance to prevent plugged nozzles. Nozzle screens come in an assortment of sizes and materials. The mesh size of a nozzle screen is dictated by the nozzle orifice size as suggested by the manufacturer's manual. As a general rule, avoid nozzle orifice sizes that require greater than a 50 mesh size (ie. 80 or 100 mesh). Since well water is usually used as a carrier source, the water may contain a small amount of sand and foreign material. A mesh of 80 or greater will easily plug and require frequent cleaning. Also, some pesticide materials may plug small nozzle openings and screens.Clean strainers frequently. A shut-off valve between the tank and suction line will allow cleaning of the strainers without draining the tank. Always replace damaged or deteriorated strainers.

PROGRESSIVE SCREEN MESH IN A SPRAYER.
Where:	Mesh
Filler Opening	12-25
Suction Line (Roller Pump)	15-40
Suction Line (Centrifugal Pump)	12-16
Discharge Line	25-100*
Nozzle	50-100*
* Nozzles requiring greater than 50 mesh size (ie. 80 or 100 mesh) are prone to frequent plugging.

 Maintenance and Care

Many pesticides cause rapid corrosion of metal components in a spraying system. Pesticides should be washed from the whole system immediately after use. Cleaning a sprayer thoroughly not only increases its life but also reduces the chance of cross contamination of chemicals and prevents crop injury. In the case of wettable powders, cleaning prevents settling and caking which may be difficult to remove once the chemical has dried.

Always end the day with an empty tank. When using the same chemical the next day, flushing the sprayer with clean water is sufficient. Always flush the sprayer onto a site listed on the pesticide label. If a different pesticide will be used, a more effective cleaning is necessary. The cleaning solution will depend on the type of pesticide. Always check the pesticide label for specific cleaning instructions.

After cleaning, remove the nozzles and flush the system twice with clean water. Clean nozzles and screens in a strong detergent solution or kerosene, using a soft brush. Use rubber gloves for your protection.

The sprayer should be protected from deterioration during the storage period. If the sprayer has no rubber components (gaskets, diaphragms, hoses, etc.), use motor oil in the final flushing to help protect from corrosion. Another alternative is to use automotive antirust for rust inhibition .This  protects against corrosion  in case all the water was not drained. Seal off any openings to prevent entry of dirt, debris or insects. Store the sprayer in a place secure from damage from other equipment or livestock. Make a list of all parts in need of replacement and order them well in advance of the next spray season.

SPRAYER CALIBRATION FUNDAMENTALS

Sprayer Calibration Fundamentals

 Facts.

• Inaccurate pesticide application rates, spray patterns and droplet size can lead to the movement of pesticides from the targeted area and reduce pesticide effectiveness.
• The first step in sprayer calibration is to determine the correct nozzle type and size.
• Nozzle material is important in reducing inaccurate applications due to nozzle wear.

Due to timeliness and effectiveness, chemical pesticide application has become a leading method of weed and insect control in  agricultural production. The continued use of pesticides in the agricultural industry has led to concerns of chemical trespassing by groundwater contamination or drift.

 Although inaccurate tank mixing causes some of these errors, a majority of the problems result from improper spray equipment calibration and worn nozzles.

Nozzle Selection

The first step in sprayer calibration is to determine the correct nozzle type and size (flow rate). Flat-fan nozzles are used for broadcast spraying of most herbicides and some insecticides where a medium droplet size is needed. Flat-fan nozzles are used for banding herbicides. Flooding type and full cone nozzles used for pre-plant herbicides produce drift-resistant large droplets, and wide nozzle spacing can be used. Hollow cone nozzles produce smaller droplets and are used to apply insecticides and contact herbicides that need to penetrate the canopy.

Inaccurate applications can be due to nozzle wear. Therefore it is important to select the correct nozzle material. Wear-resistant materials such as tungsten, carbide, ceramic and hardened stainless steel help nozzles maintain a constant flow rate after a long period of use. Nozzles made from less durable materials (plastic, brass) demonstrate increased flow rates after only a short period of spraying. For example, after 50 hours of spraying, a brass nozzle can have an increased flow rate of 10 to 15 percent, whereas a hardened stainless steel nozzle will increase only about 2 percent. The increased flow rates result from an increased nozzle orifice area. The added cost to purchase a more durable nozzle can pay for itself many times over by reducing the over-application that results from nozzle wear.

Nozzle size depends on the desired application rate, ground speed and nozzle spacing. For each nozzle type and spray angle, the manufacturer recommends spray height and nozzle spacing. Nozzle spacings of 50 and 70 CM are most common. The desired flow rate from the nozzle can be determined from the following equation;

Application rateL/Ha*Swath(M)*Speed(Km/Hr) =Flow rateL/Min

                                    600

Calibration Procedure

Spray Rig Preparation

1. Thoroughly clean the spray rig. Check for signs of rust, leaks or other problems.
2. Determine the litres needed per hectre based on the recommended rate from the pesticide label, tank size, pesticide container size, and rate of pesticide application per Ha..
3. Calculate a rough estimate of nozzle application rates based on the planned application speed and boom pressure.
4. Check all nozzles on the spray boom for signs of wear and nozzle size. Replace worn nozzles and nozzles of the wrong size for the desired application.
5. Half-fill the spray tank with water and go to the prepared field.

One Way to Calibrate a Sprayer

1. Measure the ground speed of the rig with the sprayer implement in place. (Average the travel time of the tractor in seconds over 100M in the field for two separate passes.)
2. Calculate the ground speed.
3. Measure the distance in metres between spray nozzles on the boom.
4. Calculate the desired nozzle output (l/min).
5. Catch one minute's worth of water from one or two nozzles at the operating pressure.
6. Adjust the pump pressure or ground speed until the desired output is reached.
7. Calculate the acreage covered on one tank of spray mixture.
8. Finish filling the spray tank with pesticide and carrier (usually water). Apply about one-half tankful of spray and determine if the correct amount of acreage has been covered.
9. Continue spray application; recalibrate if the first half tankful didn't cover the correct acreage.

Use small adjustments in pressure to obtain the desired nozzle flow rate within the recommended operating pressure. Operating a nozzle at excessively high pressures will produce small spray droplets susceptible to drift. Operating at excessively low pressures produces larger, less-effective spray droplets and poor spray pattern uniformity down the length of the boom.

Spray System Checks

After all the adjustments are made, fill the sprayer with water and measure the nozzle flow rates by catching the nozzle output for 1 minute. Maintaining the desired application rate is essential. Over-application results in wasted pesticide, potential groundwater contamination, and possible crop injury. Under-application can produce ineffective pest control.

Erroneous flow rates can result from damaged, worn or plugged nozzles or strainers, and spray hose restrictions between the pressure gauge and the nozzle. Clean nozzles with a toothbrush, not a pocket knife. Never blow out a nozzle with the mouth.

Check the pressure along the length of the boom. If a large pressure difference is found, look for restrictions or install a larger diameter spray hose. An accurate pressure gauge is worth the extra cost.

Field Checking

Conduct field calibration when spraying the pesticide. Start with the tank full of solution, spray a known distance in the field (at least 100m2) and determine the number of litres needed to refill the tankMultiply the used volume by 100 to determine l/Ha.

Spray Distribution Uniformity

Spray distribution uniformity is important for broadcast spraying. Uniform spray coverage eliminates weed streaking and crop injury. Concentrations up to four times the recommended amount can result from non-uniform applications. To obtain even coverage, make sure all the nozzles are the same and are equally spaced along the boom. Check each nozzle to make sure the flow rates are correct. Replace nozzles if the flow rates are 10 percent or more in error. The boom height should be adjusted to the recommended height .

Check spray uniformity by spraying water on a concrete surface and observing the amount of streaking that occurs when the water dries. Spray patterns that result in excessive accumulation below the nozzle are produced by:

1. Nozzle wear
2. Low boom height
3. Low operating pressure
4. Large nozzle spacing

Irregular spray patterns result from damaged nozzle tips, mismatched nozzles and uneven booms.

Pesticide drift is a major concern. In addition to reducing effectiveness, pesticide drift can damage non-target areas. One method to decrease drift is to use a low volatile formulation that is less likely to volatize and drift.

Pesticide drift also can be controlled by reducing the number of small droplets emitted from the sprayer. Nozzle type, angle and orientation, boom height, and operating pressure can influence the production of driftable drops. Spray thickeners can reduce drift, as can spraying at low temperatures and high humidity.