Prepared by:
James C. Barker
Professor and Extension Specialist
Biological and
Agricultural Engineering
L. Bynum Driggers
Professor and Extension Specialist
Biological and
Agricultural Engineering
Ronald E. Sneed
Professor and Extension Specialist
Biological and
Agricultural Engineering
North Carolina State University, Raleigh, NC
Publication Number: EBAE 080-81
Last Electronic Revision: March 1996 (JWM)
Advantages Several advantages result from frequent removal of wastes and associated anaerobic contaminants from production buildings. Reduced pit gases and odor improves the in-house environment, animal health and performance and employee working conditions. A reduction of these odorous gases exhausted from the building by pit ventilation systems is likely to reduce the potential for nuisance complaints. The solid buildup in the bottom of storage pits is no longer a handling problem, thereby improving labor and management efficiency. Corrosion and maintenance requirements by metallic components of the building are reduced. The capital costs of installing flush systems in new buildings is somewhat offset by the shallower underfloor pits required.
Ventilation Flushing technology should not become a substitute for ventilation. The primary purpose of ventilation is to remove moisture from a building during the winter and to control temperature during the summer. This basic requirement remains the same whether pits are flushed or not. Therefore, even though the primary source of gas and odor generation has been reduced by flushing, pit ventilation should still be provided.
Floor Type Flushing under slats or raised decks is recommended for all buildings while open floor gutter systems are a possible alternative only for gestation buildings. Disease, parasites and antibiotic transmission are potential problems where animals have direct access to the flush water.
Background Information on flush system design prior to 1980 was primarily confined to open gutter buildings less than 125 feet (ft) long with a slope of 1-2%. Variable-width, variable-slope gutters presented construction difficulties. Information for flushing longer buildings with wider underslat pits, flatter uniform slopes, and varying animal densities was limited. This article presents design criteria tailored toward individual building characteristics and constraints.
Flush Volumes Flush volumes can be determined by manure viscosity, solids carrying capacity of the flush water, manure production or animal densities, and channel slope. A relationship can be developed between the minimum viscosity for adequate waste removal and the dry matter content or solids carrying capacity of the flush water. The waste density was assumed to be the same as water. Laboratory studies were conducted to develop an empirical relationship between viscosity and dry matter content in order to establish the solids carrying capacity of the water and correspondingly the water volume needed for waste removal. The amount of manure solids to be removed from the gutter can be determined from the animal densities and liveweights. The total mass including both the flush water volume and the manure solids can now be estimated. The flush volume required is the difference between the total mass and the weight of the manure solids. Table 3 presents tabulated water volumes recommended for varyi ng channel slopes and flush frequencies.
Detailed design procedures and assumptions are explained by Barker and Driggers, 1980.
______________________________________________ Channel Channel Flow Flow Min volume slope width depth rate for 10-sec discharge ______________________________________________ % feet inches gpm gallons 0.5 2 3.5 783 130 3 3.2 1070 178 4 3.0 1367 228 5 3.0 1666 278 6 2.9 1967 328 8 2.9 2571 428 10 2.8 3175 529 1.0 2 1.9 416 69 3 1.8 594 99 4 1.7 773 129 5 1.7 953 159 6 1.7 1132 189 8 1.7 1492 249 10 1.7 1853 309 1.5 2 1.3 295 49 3 1.3 427 71 4 1.2 560 93 5 1.2 693 115 6 1.2 825 138 8 1.2 1091 182 10 1.2 1357 226 2.0 2 1.0 233 39 3 1.0 340 57 4 1.0 447 74 5 1.0 554 92 6 1.0 661 110 8 1.0 875 146 10 1.0 1089 182 ______________________________________________
______________________________________________________ Channel Number of flushes per day Slope _____________________________________________ 1 2* 3 4 6 12 ______________________________________________________ % ------gallons per 100-lb hog per flush------ 0.5 3.21 1.61 1.07 0.80 0.54 0.27 1.0 2.97 1.48 0.99 0.74 0.50 0.25 1.5 2.84 1.42 0.95 0.71 0.47 0.24 2.0 2.75 1.38 0.92 0.69 0.46 0.23 ______________________________________________________ * Recommended minimum flush tank design capacity.
Hydro-Discharge Nomimal Discharge Pipe Diameter, inches staticPipe Exit ____________________________________________________________ Head Velocity 2 3 4 6 8 10 12 15 ____________________________________________________________________________ feet ft per sec ____________________gallons per minute____________________ 1 4.01 39 88 158 353 628 982 1416 2210 2 5.68 56 125 222 500 889 1389 2000 3126 3 6.95 68 153 272 612 1089 1702 2450 3828 4 8.02 78 177 314 708 1258 1964 2828 4420 5 8.98 88 198 352 791 1406 2197 3163 4942 6 9.82 96 217 385 866 1540 2406 3463 5414 7 10.62 104 234 416 936 1663 2599 3742 5847 8 11.35 111 250 444 1000 1778 2778 4001 6251 ____________________________________________________________________________
Small-Diameter Single Siphon Figure 2 depicts this tank which offers automated dosing action with no moving parts. At the beginning of the fill cycle, air is trapped under the bell. As the tank fills with water, the air under the bell is slowly forced out of the siphon pipe until siphoning is triggered and the tank empties. Tank materials can either be metal or concrete. These tanks have met with mixed success since they are very sensitive to construction miscues and become impractical for long buildings especially in the flatter Coastal Plain regions due to the steep pit slopes required for cleaning. Table 6 gives construction dimensions.
Large-Diameter Multiple Siphon A larger, more successful version of the siphon tank (figure 3) allows multiple large-diameter discharge pipes to emerge from a common ground-level tank and siphon bonnet. Tank construction including the siphon bonnet is usually reinforced concrete. Initial positioning of the 2-in siphon trigger tube and discharge pipe relative to the pit floor and tank floor is important. This tank is more suited to flushing wider pits on flatter slopes. Table 7 gives construction dimensions.
Tipping Bucket Rotating tilt tanks similar to the sketch in figure 4 dump when they fill with water to a depth where the center of gravity is above the tank pivot point. Unless the tanks are constructed with a lid and controlled discharge outlet, the water is discharged at once, and any manure remaining after the first wave of water down the gutter will not be removed from the pit. These type of tanks are recommended primarily for small volume applications such as farrowing houses or nurseries. Metal tanks are expensive to construct, subject to corrosion, and require maintenance due to their frequent violent rotations.
Valved or Gated Discharge These tanks offer the advantage of simple ground level reinforced concrete or concrete and steel reinforced cinder block construction and the flexibility to either be flushed manually or with commercially available flush gate mechanisms. These tanks may be built adjacent to the end of the building using the building wall as a common wall to the tank or they may be free-standing unattached to the building. Figure 5 depicts a simple and reliable water-weighted valve opening mechanism which offers flexibility for opening multiple valves simultaneously at varying valve diameters without requiring electromechanical actuation. Figures 5a through 5e show the operating sequence of this valve opener and the adjustments necessary for it to function.
_____________________________________________________________________________ Tank Tank Depth, feet Width________________________________________________________________________ 2 3 4 5 6 7 8 9 10 _____________________________________________________________________________ feet ____________________gallons per foot of tank length____________________ 2 30 45 60 75 90 105 120 135 150 3 45 67 90 112 135 157 180 202 224 4 60 90 120 150 180 209 239 269 299 5 75 112 150 187 224 262 299 337 374 6 90 135 180 224 269 314 359 404 449 7 105 157 209 262 314 367 419 471 524 8 120 180 239 299 359 419 479 539 598 9 135 202 269 337 404 471 539 606 673 10 150 224 299 374 449 524 598 673 748 12 180 269 359 449 539 628 718 808 898 14 209 314 419 524 628 733 838 943 1047 16 239 359 479 598 718 838 958 1077 1197 18 269 404 539 673 808 943 1077 1212 1346 20 299 449 598 748 898 1047 1197 1346 1496 _____________________________________________________________________________
____________________________________________________________________________ Tank Tank Depth, feet Diameter ___________________________________________________________________ 2 3 4 5 6 7 8 9 10 ____________________________________________________________________________feet ____________________gallons____________________2 47 71 94 118 141 165 188 212 235 3 106 159 212 264 317 370 423 476 529 4 188 282 376 470 564 658 752 846 940 5 294 441 588 734 881 1028 1175 1322 1469 6 423 635 846 1058 1269 1481 1692 1904 2115 7 576 864 1152 1439 1727 2015 2303 2591 2879 8 752 1128 1504 1880 2256 2632 3008 3384 3760 9 952 1428 1904 2379 2855 3331 3807 4283 4759 10 1175 1763 2350 2938 3525 4113 4700 5288 5875 12 1692 2538 3384 4230 5076 5922 6768 7614 8460 14 2303 3455 4606 5758 6909 8061 9212 10364 11515 16 3008 4512 6016 7520 9024 10528 12032 13536 15040 18 3807 5711 7614 9518 11421 13325 15228 17132 19036 20 4700 7050 9400 11750 14100 16451 18801 21151 23501 ____________________________________________________________________________
____________________________________________ Pipe Symbol diam. _____________________________________ a b c e f g h i ____________________________________________ ______________inches______________ 2 36 48 1.5 5.0 1.0 6 9 48 60 1.5 6.0 1.0 8 9 60 72 1.5 6.5 1.0 9 9 3 36 48 1.5 6.0 1.0 9 11 48 60 1.5 7.5 1.0 12 11 60 72 1.5 8.5 1.0 14 11 4 36 48 1.5 8.0 1.0 14 12 48 60 1.5 7.5 1.0 12 14 60 72 1.5 8.0 1.0 13 15 6 36 48 2.0 9.5 1.5 18 16 48 60 2.0 9.5 1.5 17 18 60 72 2.0 9.5 1.5 16 20 8 36 48 2.5 9.5 2.0 17 22 48 60 2.5 9.5 2.0 17 24 60 78 2.5 11.5 2.0 20 24 ____________________________________________
Nom pipe dia,in 4 6 8 _______________________________________________________________________________ No. disch pipes 1 2 3 4 6 8 1 2 3 4 6 8 1 2 3 4 6 8 _______________________________________________________________________________ symbol ----------siphon dimensions, inches----------- a 12 12 18 18 24 24 12 18 24 24 30 36 18 24 30 30 36 42 b 3.3 2.53.1 2.8 3.3 3.4 2.9 2.6 3.4 2.9 2.9 3.3 2.9 2.8 2.5 3.4 2.6 3.2 c 39 39 39 39 39 39 39 39 39 40 40 42 39 39 40 42 42 42 d 6.714.57.911.2 8.712.616.112.4 9.614.113.111.710.111.210.515.616.415.8 e 23 16 22 19 21 17 14 18 20 15 16 15 20 19 19 11 11 11 f 3 3 3 3 3 3 3 3 3 4 4 6 3 3 4 6 6 6 g 6 5.35.8 5.6 4.3 6.3 5.7 5.3 6.1 6.7 6.5 5.8 5.7 5.5 6.3 9.2 8.2 7.9 h 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 Q*, gpm 293 589880117617622350 63712761903256438265101107921593268439065188691 _______________________________________________________________________________ Nom pipe dia,in 10 12 ____________________________________________________________________________ No. disch pipes 1 2 3 4 6 8 1 2 3 4 6 8 ____________________________________________________________________________ symbol ------------siphon dimensions, inches------------- a 18 30 36 36 48 54 24 30 42 48 54 60 b 2.7 3.0 2.5 2.7 2.6 2.6 3.3 3.2 3.1 2.8 3.4 2.5 c 40 40 42 42 42 42 40 42 42 42 42 42 d 18.3 11.0 11.5 17.3 13.4 14.4 12.7 17.8 11.9 12.2 15.6 17.5 e 11 18 16 10 13 11 16 9 15 15 9 6 f 4 4 6 6 7 8 4 6 6 6 8 10 g 6.4 6.8 8.3 8.4 6.7 7.2 7.1 8.9 8.8 8.5 7.8 8.5 h 6 6 6 6 7 8 6 6 6 6 8 10 Q*, gpm 1691 3374 5147 6854 10211 13614 2368 4805 7212 9635 14375 19166 ____________________________________________________________________________ * Discharge or flow rate, gallons per minute (gpm)
Piping System Use nonmetallic pipe and fittings. Polyvinyl chloride (PVC,white), polyethylene (PE, black), and acrylonitrile- butadiene-styrene (ABS,black) are typical pipe materials being utilized. The black PE and ABS pipes are reported to give slightly less salt troubles than the PVC. The minimum pressure rating of recharge pipes should be 80 psi. Consult with pump experts to size pipe diameters large enough to maintain flow velocities between 3-5 feet per second. The minimum pipe diameter at any point in the system should be 1.5 inches. Table 7 gives flow capacities for various PVC Class 125 sizes to keep the flow velocity between 3-5 feet per second. Minimize sharp bends such as elbows and tees with rolled PE pipe and long sweep elbows for direction changes. Piping systems not in continuous use should be planned for draining between pumping events.
Electrostatic Charges Direct grounding of the pump housing helps to discharge any static charges or stray voltage believed to contribute to salt deposition. A metal ground rod should be driven 10-12 feet into moist soil near the lagoon edge. Check cable edge. Check cable connections at the ground rod and pump periodically for corrosion.
__________________________________ Nominal pipe Flow velocity, fps diameter, in 3 5 __________________________________ -------gpm--------- 1.5 25 40 2 37 60 2.5 55 90 3 80 130 4 130 220 6 285 475 __________________________________
Acid Cleaning Salts can be dissolved from internal pump and pipe surfaces with dilute acid treatments. Removal of heavy buildups require several dosings followed by flushing of the acid and dissolved salt solutions or an acid recirculation loop. A recirculation loop consists of an acid-resistant reservoir tank with capacity to supply enough solution to fill the pipe length to be cleaned as determined from Table 8 plus some reserve to keep the pump primed. The flush pump suction is switched from the lagoon and connected to the bottom of the acid tank with a quick-connect coupling. A 1-inch line from the end of each pipe section treated returns acid to the tank.
Muriatic (hydrochloric) acid (30% (20o) technical grade) is diluted (one gallon acid added to 9 gallons water). Extreme caution must be exercised since mixing of acids with water can be very hazardous. Never try to add water to the concentrated acid. Always partially fill the tank with water, then add the acid to the water very slowly. Heat will be generated. Eye protection is advisable. Recirculations ranging from two hours to overnight will be required depending on the degree of salt buildup. This dilution should not hurt metal although prolonged contact should be avoided. A heavy buildup may render the acid usable only one time; although it should be retained after the first use and reused to see how much strength remains. Spent acid may be dumped to the lagoon.
_____________________________ Nomimal pipe Gallons per diameter, in foot of length _____________________________ 1.0 0.06 1.5 0.13 2.0 0.20 2.5 0.30 3.0 0.44 4.0 0.73 6.0 1.58 _____________________________
_______________________________________________ Nominal Slope of Pipe, % Drainpipe ____________________________________ Diameter 0.1 0.5 1.0 1.5 2.0 _______________________________________________ inches --------gallons per minute-------- 2 4 9 13 16 19 3 12 28 40 48 56 4 27 60 85 105 121 6 80 179 253 309 357 8 172 385 544 666 769 10 312 697 986 1210 1390 12 507 1130 1600 1960 2270 14 765 1710 2420 2960 3420 15 919 2060 2910 3560 4110 16 1092 2440 3450 4230 4880 18 1490 3340 4730 5790 6690 20 1980 4420 6260 7660 8850 22 2550 5700 8070 9880 11400 24 3220 7200 10200 12500 14400 _______________________________________________
Specific conclusions are:
Not Included:
Figure 2. Small-diameter single siphon flush tank
Figure 3. Large-diameter multiple siphon flush tank
Figure 4. Free-swinging flush bucket (Univ. of Tenn. Plan No. T4044)
Figure 5. Ground level flush tank with water weighted valve opener
Figure 6. High-volume flush pump distribution header
Figure 5a. Beginning of fill cycle. Tank empty; valve closed; 2-3" slack in
valve chain; reservoir empty.
Figure 5c. Just prior to valve opening. Tank full; valve closed; valve chain
taut; water rapidly filling reservoir.
Figure 5e. Just prior to valve closing. Tank empty. When all water drains
from reservoir, valve closes, valve chain becomes slack, and fill
cycle begins.
Figure 5b. Water beginning to enter reservoir. Tank nearly full; valve
closed; 2-3" slack in valve chain; some water in reservoir.
Figure 5d. Valve fully open. Tank emptying; valve open; valve chain taut;
reservoir about 2/3 full of water.
Figure 7. Pit drain standpipe valve
Figure 8. Waste collection box
Figure 9. Pit drain collection gutter
Figure 10. Drainpipe connection