BULLOCK DRIVEN WATER PUMP

Transcription

1 BULLOCK DRIVEN WATER PUMP 1 AKSHAY MALVIYA, 2 PRIYA SONI Department of Industrial & Production Engineering, Jabalpur Engineering College, Ranjhi, Road, Jabalpur, India Department of Industrial & Production Engineering, Jabalpur Engineering College, Ranjhi Road, Jabalpur, India Abstract In rural areas where there is no or inadequate electric supply and water level in much below the ground level, the improper irrigation is the major problem in such areas. This mechanism does not depend on electricity and advocates the usage of manual effort. Keywords Cylinder, Bearing, Wire rope, Connecting Rods, Pipes, Clamps, Plunger, Pulley Tank, Foot Valve, S-Link. I. INTRODUCTION The innovation results to the modification in basic design of hand pump to give continuous supply of water from deep bore well. The whole pump mechanism is divided into two parts namely, Pump Driving Mechanism and Water Lifting Mechanism. The pump driving mechanism consists of one two horizontal spur gear meshing together attached to a S-Link. The horizontal gear is driven by bullock. This horizontal gear drives the other gear of comparatively smaller diameter which in turn drives the S-link, through which the two rollers are attached. These rollers have attachments in them for the clamping of the wire rope. II. MAIN COMPONENTS A. Cylinder Cylinders are the main component in this mechanism, two cylinders of diameter 2.5inches each are used for the suction and lifting processes involved. The cylinders are made up of steel. The cylinder has two main components namely- the Check Valve and the Piston Cum Valve arrangement. The check valve arrangement is stationary with respect to cylinder whereas the piston cum valve reciprocates for suction and lifting alternately. Figure 1.1 shows the basic component of cylinder. B. Bearing The purpose of a bearing is to reduce friction, on rotating S-Link. Here Ball bearing is used in the hub connecting the gear and the S-link for friction less rotational movement or for smoother functioning and increased efficiency. Two Bearings are also used for providing free or frictionless movement for reciprocating wire ropes. Figure 1.1 Cross sectioned View of Cylinder Figure 1.2 Ball Bearing 69

2 C. Wire rope (5 mm) A 5mm wire rope is used here. A 5mm rope is capable of lifting weight of water column in the pipe. The wire rope replaces the connecting rods that were used in conventional hand pump. The wire rope is flexible and can bear a tension force produced by up to 750 kg of water in the column. H. Pulley Tank A casing of 5 inch inner diameter was taken and a pulley is placed inside it so that the wire rope can have a free to and fro working of the mechanism i.e. the suction and lifting process. This casing is then attached to the inlet of both the cylinders through separate pipes. D. Connecting Rods Basically there are two connecting rods on each cylinder. One connecting rod is fixed to the one side of the piston cum valve whereas the second connecting rod is connected to the other side. The connecting rod at upper side is welded to the wire rope and the connecting rod which is connected to the lower side is made to join from the plunger or check valve through a washer and then again it is connected to the wire rope which passes through a pulley and again connected to the same assembly on the other side. E. Pipes (1.25 inches, 10 Ft.) Two PVC or Grey iron (G.I.) pipes are connected to the cylinders. From these pipes the water is lifted up and these two pumps are joined to the single discharging outlet. The weight of cylinder and the whole water lifting mechanism is on the pipes. These pipes should withstand high varying loads. I. Foot Valve Foot valve is a type of check valve and is placed at the bottom of the pump. Unlike other valves, a foot valve is created with a larger flow area than the actual pipe size to make sure that there is less head loss. Foot valves are either made of PVC plastic or stainless steel, and they are known for keeping the continuous presence of suction within the pump. Foot valves are used to maintain hydraulic pressure to keep the water flow in accordance with the given settings or configurations. There are instances where the pressure can actually pop the valve out and cause major leakage; thus, it is important to use the right kind of material in the tubing to be able to support the force within the valve. J. S-LINK The pistons are connected to the S-link through separate wires, which when rotated provides the reciprocating motion to the piston. The rotation of the S-link is provided by the gear arrangement which is powered by bullock. F. Clamps Clamps are used to connect the wire rope to the rollers and the connecting rods tightly. Wire rope connected to the rotating rollers is reciprocated. G. Plunger For this mechanism the plunger of normal pump s cylinder is modified. Generally there is only a single threaded joint rod is present in the plunger but in order to synchronize both plungers of the two cylinders threading is done both sides of both plunger. 70 Fig: S-LINK

3 III. COMPARISON OF CONVENTIONAL HAND PUMP & TWO CYLINDER ASSEMBLY There are some important design innovations in the pump which makes continuous discharge of water possible. Some important design features of the pump are as follows:- In Conventional Hand Pumps, the piston assembly is connected to the handle with the help of interconnecting solid rods known as Connecting Rod. While giving reciprocating motion to the piston these rods are alternately subjected to the tensile and compressive loads. In the proposed design these connecting rods will be replaced by wire rope, which will be subjected to only tensile loads. Two Cylinder Assembly is used for alternate suction and lifting of water. This makes the discharge of water continuous, whereas in case of the conventional pumps only one cylinder is used, because of which the discharge of water is intermittent. Both the pistons are connected to the S-link through separate wire ropes; the rotation of S-link provides the reciprocating motion to the piston. The rotation of the S-link is provided by the gear arrangement which is powered by bullock. Since the reciprocating motion of the piston is only through alternate push and pull of the connecting rod, the problem of buckling of connecting rod in deep bore wells during the push of the rod is totally eliminated. It is therefore possible to lift water from very deep bore wells with a continuous discharge. Picture of Pump Driving Mechanism B. Water lifting mechanism The water lifting mechanism is a dual pump. It works by suction of water into the cylinder through a check valve on the up-stroke, and the piston cum valve is held closed by the weight of the water above it, simultaneously, the water above the piston is propelled out of the pump. On the down-stroke, the lower check valve is held closed by both the water pressure and its own weight, while the similar valve in the piston is forced open as the trapped water is displaced through the piston ready for the next upstroke. IV. PRINCIPLE OF MECHANISM The principle of the mechanism is that the water is lifted in the pipe using two cylinder assemblies involve suction and lifting process. The water suction occurs at the upstroke of the piston and the water occupies the space inside the cylinder and on down stroke the piston pressurizes the water column inside the cylinder which in turn opens the piston valve and the water shifts above the valve. Now when the second upstroke occurs, this water column is raised by height equal to the stroke length of piston. This process occurs alternately in both the cylinders. This results in the lifting of water column in both the pipes which are connected to a single outlet, thus giving continuous flow of water. The reciprocating motions to the pistons in two cylinders are provided by wire rope which is driven by Pump Driving Mechanism. V. MECHANISM A. Pump Driving Mechanism The mechanism is bullock driven. The horizontal spur gear is rotated by bullock. The horizontal spur gear is further connected to another spur gear of smaller diameter for increased R.P.M. required. Figure 1.3 shows the snapshot moment of the working cylinders. The cylinder in left position is engaged in a suction process whereas the right hand side cylinder is pushing the water upwards by moving in the opposite direction. The two cylinders are hung by the means of clamping on G.I. pipes. Through these pipes the wire rope also passes. The mouths of the two pipes are connected to a single opening of same diameter as that of the pipes. The water comes out of both the pipes alternately, which in turn results in a continuous water supply. The wire rope goes through the pulley and helps in smooth operation of the system. The valves are so designed that there is very negligible leakage of water. Since due to wire rope considerable leakage would have been observed, 71

4 the covering part of the wire rope inside the cylinder is replaced by the solid rod. Rubber washers are used to prevent leakage. The complete mechanism is made to stand in a very rigid mounting so that no slipping and vibrations occurs. VI. INSTALLATION AND MAINTENANCE INSTALLATION OF WATER LIFTING MECHANISM. 1. The piston comes with a pair of washers. If not, they can be fitted to the pistons by opening a threaded joint. After the washers are fitted, the check valve assembly is threaded to the bottom front of the cylinder and then piston cum valve assembly along with the two connecting rods is fitted to the cylinder. Finally this whole arrangement is confined into the cylinder by fitting tightly an octagonal washer at upper front. 2. The cylinder assemblies are attached to the G.I. pipes through which the water is lifted. G.I. pipes should be used so that their strength is enough to bear the load of water lifting mechanism. 3. The wire should be clamped properly and tightly, where there are joints between rod and wire rope. Primarily to this clamping the path of the wire has to be set as shown in the design. 4. The pump cylinder should be installed below the lowest anticipated level of the water to eliminate any pollution hazard associated with priming the pump with no potable water. 5. The length of the installed pump rod should be such that the piston does not hit the top of the cylinder when the pump piston is at the bottom of its travel. The constant pounding could cause the pump rod to separate at a threaded joint or damage the pump cylinder or piston. INSTALLATION OF PUMP DRIVING MECHANISM. 1. As described earlier in section mechanism the pump driving mechanism is the arrangement of two spur gears in a rigid structure to convert the rotary motion into the reciprocating motion (or alternate pulling of the wire rope) of pistons with the help of S- Link. 2. The wire rope is clamped to the rollers present in the S-Link of the pump driving mechanism, tightly. This clamping is done in such a way that the two pistons, at the time of installation, maintains the phase difference of 180 degree i.e. when cylinder on left hand side is at its bottom dead center, at the same time cylinder on the right hand side is on its upper dead center. Large error in this step would lead to distortion of the system components. Like any other piece of machinery, hand pumps have maintenance requirements. Common maintenance procedures for hand pumps are described in the following points. 1) Well Cleaning or Flushing Some wells are not adequately cleaned at the low pumping rate of hand pumps. Accumulations of sediment, rust particles, etc., eventually may affect the physical quality of the well water. At some sites, periodic cleaning of the well can be beneficial. 2) Pump Stand Nuts and bolts on the stand should be tight. 3) Disinfection of the Well The well should be disinfected whenever the pump stand is raised or removed for maintenance. Washers- After very long time run of the pump the leather washers may ruin off and thus may lead to the poor suction and lifting capacity. So the washers may be changed if efficiency of the pump seems to reduce. VII. CALCULATION Depth =200ft (60.96m) Diameter Of cylinder =0.032m. Area = m2 Volume of water to be lifted =Area *Depth = ( )*60.96 = m3 Pressure of this much volume of water = p(rho)gh Where; p(rho)=density of water=1000kg/m3 g=gravity=9.81m/s2 h=height of water column=60.96m Pressure = N/m2 So, Work = Pressure *Volume = ( )* = kn-m MAINTENANCE OF THE SYSTEM Picture of installed Pump Assembly 72

5 CONCLUSION Though this mechanism is labor intensive but still it results as effective irrigation equipment. By using two cylinders, continuous discharge of water is possible. Reciprocating motion of the piston is through the pull of wires, unlike the conventional system where connecting rods are used to alternately push and pull the piston. This makes the system more effective in lifting water from deep bore wells with low initial installation cost and low maintenance cost. This continuous discharge is very helpful for irrigation especially in flood irrigation used in vegetable farms. The water obtained can also be stored in a tank for short term usage. 73