BERMAD > Centro de Conhecimento > Estudos de Caso > Modernização da Infraestrutura de Irrigação em Aragão, Espanha – Consórcio de Irrigação CCRR Callén

Estudos de Caso

Modernização da Infraestrutura de Irrigação em Aragão, Espanha – Consórcio de Irrigação CCRR Callén

Roger Molist

Background From Open Channel Irrigation to a Pressurized Network

The transformation of a 1,872-hectare irrigation consortium from open channels to a fully pressurized system

CCRR Callén is an irrigation consortium located in Huesca province, Aragón, northeastern Spain, within the Ebro basin. This region is characterized by a semi-arid Mediterranean climate, where irrigation is essential for sustaining stable agricultural production, particularly for cereal and forage crops.

Like many irrigation communities in Aragón that have modernized in recent years, CCRR Callén operates where water efficiency and hydraulic reliability are critical because of climatic variability and seasonal peak demand.

The transformation of a 1,872-hectare irrigation consortium from open channels to a fully pressurized system

The consortium serves 1,872 hectares and includes 70 farmers growing corn, barley, wheat and alfalfa. Before modernization, irrigation was based on open channels and manual ditch operation. While simple, this system was inefficient, labor-intensive and incompatible with modern pressurized irrigation methods such as sprinkler systems.

Between 2014 and 2015, the consortium implemented a comprehensive modernization project with a total investment of approx. €9.5 million, 65 percent of which was publicly funded through Spanish and European programs. The objective was to transition from open channel distribution to a fully pressurized irrigation infrastructure capable of delivering water reliably and efficiently across the entire irrigated area.

The upgraded system includes:

A regulating reservoir, 8 meters high with a storage capacity of 160,000 m³, supplied from the Cinca open channel
A pumped distribution network divided into two pressure sectors
Sector A operating at 7.0 bar and 613 l/s
Sector B operating at 4.5 bar and 968 l/s
Pumping lines equipped with five pumps per line, each fitted with variable frequency drives

This transformation significantly increased hydraulic complexity compared to the former gravity-based system and required advanced control and protection mechanisms throughout the network.

The Challenge Ensuring Hydraulic Stability in a Modern Irrigation Infrastructure

Addressing water hammer, air control and variable flow conditions across 70 farms

The transition to a pressurized, pumped irrigation system introduced multiple hydraulic challenges.

Dual Pressure Sector Management

The system was designed with two distinct operating pressure zones to maximize pumping efficiency. However, this required strict pressure regulation and surge mitigation during pump start up, shutdown and dynamic demand variations across the two pressure zones.

Surge Risk in Pumped Operation

Unlike the former open-channel system, the new configuration was exposed to water hammer risk. Sudden pump shutdowns, especially during electrical failures, could cause damaging pressure transients.

A dedicated surge analysis was performed to determine the correct sizing and positioning of surge anticipating valves and air valves throughout the network.

During commissioning, it was confirmed that system pressure could drop below the pilot setting in certain operating scenarios. This required upgrading the surge protection valves to a low pressure solenoid control version, preventing unnecessary valve opening and ensuring reliable performance under reduced pressure conditions.

Air Management Under Low Pressure

Because the elevation difference between the regulating reservoir and the pumping station is limited, some air valves were required to seal perfectly at very low pressures, as low as 1 meter water column. Proper air evacuation and vacuum protection were essential to prevent air accumulation, pressure wave amplification and pipeline stress.

Variable and Very Low Flow Conditions

Each irrigation plot required independent pressure reduction and flow limitation. During some irrigation turns, very low flow conditions could occur, particularly when small plots were supplied simultaneously. These conditions can contribute to hydraulic instability if not properly managed.

The hydraulic layout was therefore designed to ensure stable operation even under low flow demand scenarios.

Transition to Remote Irrigation Control

The old ditch-based system required manual operation. The new infrastructure required coordinated remote control of irrigation turns, synchronized with pumping operation and hydraulic constraints across the network.

The Solution Integrated Surge & Hydraulic Control

Integrated Hydraulic Control & Surge Protection

BERMAD supplied a comprehensive hydraulic control solution designed to meet the specific requirements of CCRR Callén.

Surge Protection

Two DN150 model 735-M Surge Anticipating Valves were installed on each branch of the network.

These pilot-operated valves were configured with dual pilots and upgraded with low pressure solenoid control backup to ensure proper functionality even when system pressure dropped below standard pilot settings. The final configuration was based on the system surge analysis to ensure optimal protection against transient events.

Air Flow Optimization

A total of 159 units of C70 Combination Air Valves, ranging in size from 2” to 6”, were installed across the network.

These air valves provide:

Protection against vacuum formation
Efficient air evacuation during filling
Prevention of air pocket accumulation
Reduction of pressure surge amplification

Special attention was given to locations requiring reliable sealing at extremely low dynamic pressures.

Plot Level Flow and Pressure Control

185 Units of IR-972 Hydrometers were installed throughout the consortium.

Each unit performs three functions:

Reduces system pressure down to 4 bar at the plot level
Limits the maximum flow delivered to each farmer
Measures water consumption

The consortium remotely controls each hydrometer and organizes irrigation turns according to planned schedules.

In addition, 88 Combination Air-Release units (ARC) were installed, reinforcing air management at the plot level and contributing to protection against vacuum conditions and air accumulation. The selected 400 series valves allow farmers to locally open and close the supply to meet their specific operational needs. This structure enables centralized scheduling with plot-level flexibility and precise consumption control.

Results – Reliable & Efficient Irrigation Performance

The modernization project transformed CCRR Callén from a manually operated open-channel scheme into a fully pressurized, hydraulically stable and remotely controlled irrigation infrastructure.

The upgraded system:

Ensures continuous and reliable water delivery across 1,872 hectares
Enables implementation of advanced irrigation techniques
Prevents oversupply and reduces water waste
Protects the network against surge and vacuum damage
Optimizes pumping efficiency through sector-based pressure management
Allows 24/7 monitoring and operational control

According to Sarit Hatzbany, Application Engineer at BERMAD,

“Following completion of the modernization project, each farmer now receives water at the required timing, quality and pressure, without waste or oversupply. The optimized pumping strategy also reduced energy consumption, improving both the economic and environmental performance of the consortium.”

CCRR Callén is a strong example of irrigation modernization in Aragón, showing how advanced hydraulic control, surge protection and air management enable the successful transition from traditional open channels to a resilient and efficient pressurized irrigation infrastructure.