CCET DIPLOMA IN MECHANICAL ENGINEERING

Major project

On

PEDAL POWERED WATER PUMP

Submitted To : Submitted By: Mr. D.K. Soni Jaspreet Singh-(5328/12)

Mahesh Kumar-(5329/12)

Mohit Mahajan-(5330/12)

Mukesh Sumra-(5331/12)

Neeraj Kumar-(5333/12)

Nikhil Arora-(5334/12)

CANDIDATE’S DECLARATION

We hereby declare that major project which is presented on this report entitled “PEDAL

POWERED WATER PUMP” submitted in partial fulfilments of requirements of the

award of the Diploma in MECHANICAL ENGINEERING to the Punjab State Board

of Technical Education & Indusrial Training ,Sector-36-A, Chandigarh, is an authentic

record of our own work carried at Chandigarh College Of Engineering & Technology,

Sector-26,Chandigarh campus is carried out under the supervision of Mr. D.K. Soni

The material embodied in this project work has not been submitted to any other

institution for award of any Diploma/ Degree.

Place :

Date:

This to certify that above statement made by the candidate is best to my knowledge.

Guided By:

Mr. D.K. Soni

(Lecturer)

ACKNOWLEDGEMENT

We express our sincere thanks & profound gratitude to Mr. D.K. Soni for contributing

his valuable time for completing the project “PEDAL POWERED WATER PUMP”

successfully.

Our special thanks to Mr. Chaman Lal , H.O.D. Mechanical for his encouragement

during the project.

Finally we thank all unmentioned names & visible names who helped us in bringing this

major project report to form.

Last but not the least I wish to avail myself this opportunity, express a sense of gratitude

& love to my friends and my beloved parents for their mutual support , strength, and help

for everything.

Place : Chandigarh

Date:

CERTIFICATE

Certified that the present project work entitled “PEDAL POWERED WATER

PUMP”

Submitted by

Jaspreet Singh-(5328/12)

Mahesh Kumar-(5329/12)

Mohit Mahajan-(5330/12)

Mukesh Sumra-(5331/12)

Neeraj Kumar-(5333/12)

Nikhil Arora-(5334/12)

in partial fulfilments of requirements of the award of the Diploma in MECHANICAL

ENGINEERING to the Punjab State Board of Technical Education & Indusrial

Training ,Sector-36-A, Chandigarh, is an authentic record of our own work carried out

in Final Year of Diploma in Mechanical Engg. Under my supervision & guidance.

Signature

CCET

Sector-26, Chandigarh

Place: Chandigarh Date:

CONTENTS

SR.No. CONTENTS

1. Introduction to Pumps

2. Types of pumps

3. Centrifugal pump

4. Reciprocating -(Piston Plunger type pump)

5. Working principle of Reciprocating pump

6. Major components Used in the project

7. Energy Losses in Pipe Fittings and pump

8. Performance Terms & Definitions

9. Trouble shooting Pump problems

10. Actual Project Image

11. Workshops, tools & Extra Materials Used

12. Total Cost of Project

13. Conclusion

INTRODUCTION

Pumps – convert mechanical energy into fluid energy.

Pumps come in a variety of sizes for a wide range of applications. They can be

classified according to their basic operating principle as dynamic or displacement

pumps. Dynamic pumps can be sub-classified as centrifugal and special effect pumps.

Displacement pumps can be sub-classified as rotary or reciprocating pumps.

In principle, any liquid can be handled by any of the pump designs. Where different

pump designs could be used, the centrifugal pump is generally the most economical

followed by rotary and reciprocating pumps. Although, positive displacement pumps

are generally more efficient than centrifugal pumps, the benefit of higher efficiency

tends to be offset by increased maintenance costs.

Since, worldwide, centrifugal pumps account for the majority of electricity used by

pumps, the focus of this chapter is on centrifugal pump.

CENTRIFUGAL PUMP

A centrifugal pump is of a very simple design. The two main parts of the pump are the

impeller and the diffuser. Impeller, which is the only moving part, is attached to a shaft

and driven by a motor. Impellers are generally made of bronze, polycarbonate, cast iron,

stainless steel as well as other materials. The diffuser (also called as volute)

houses the impeller and captures and directs the

water off the impeller.

Water enters the center (eye) of the impeller and

exits the impeller with the help of centrifugal

force. As water leaves the eye of the impeller a

low-pressure area is created, causing more water

to flow into the eye. Atmospheric pressure and

centrifugal force cause this to happen. Velocity

is developed as the water flows through the

impeller spinning at high speed. Thewater

velocity is collected by the diffuser and

converted to pressure by specially designed passageways that direct the flow to the

discharge of the pump, or to the next impeller should the pump have a multi-stage

configuration.

The pressure (head) that a pump will develop is in direct relationship to the impeller

diameter, the number of impellers, the size of impeller eye, and shaft speed. Capacity is

determined by the exit width of the impeller. The head and capacity are the main

factors, which affect the horsepower size of the motor to be used. The more the quantity

of water to be pumped, the more energy is required.

A Centrifugal Pump

RECIPROCATING PUMP

Reciprocating pumps are those which cause the fluid to move using one or more

oscillating pistons, plungers or membranes (diaphragms).

To 'Reciprocate' means 'To Move Backwards and Forwards'.A

'RECIPROCATING' pump therefore, is one with a forward and backward

operating action.The simplest reciprocating pump is the 'Bicycle Pump', which

everyone at some time or other will have used to re-inflate their bike tyres.

Reciprocating-type pumps require a system of suction and discharge valves to

ensure that thefluid moves in a positive direction. Pumps in this category range

from having "simplex" onecylinder, to in some cases "quad" four cylinders or

more. Most reciprocating-type pumps are"duplex" (two) or "triplex" (three)

cylinder.

Furthermore, they can be either "single acting" independent suction and discharge

strokes or"double acting" suction and discharge in both directions. The pumps

can be powered by air,steam or through a belt drive from an engine or motor

This type of pump was used extensively in the early days of steam propulsion

(19th century) as boiler feed water pumps

Reciprocating pumps are now typically used for pumping highly viscous fluids

including concrete and heavy oils, and special applications demanding low flow

rates against high resistance.

Reciprocating pump

Working Principle

Reciprocating pump is a positive displacement pump, which causes a fluid to move by

trapping a Fixed amount of it then displacing that trapped volume into the discharge

pipe. The fluid enters a pumping chamber via an inlet valve and is pushed out via a

outlet valve by the action of the piston or diaphragm. They are either single acting;

independent suction and discharge strokes or double acting; suction and discharge in

both directions. During the suction stroke the piston moves left thus creating vacuum in

the Cylinder. This vacuum causes the suction valve to open and water enters the

Cylinder. During the delivery stroke the piston moves towards right. This increasing

pressure in the cylinder causes the suction valve to close and delivery to open and water

is forced in the delivery pipe. The air vessel is used to get uniform discharge.

Reciprocating pumps are self priming and are suitable for very high heads at low flows.

They deliver reliable discharge flows and is often used for meteringduties because of

constancy of flow rate. The flow rate is changed only by adjusting the rpm of the driver.

Working Principle of Reciprocating Pump

These pumps deliver a highly pulsed flow. If a smooth flow is required then the

discharge flow system has to include additional features such as accumulators. An

automatic relief valve set at a safe pressure is used on the discharge side of all positive

displacement pumps.

The performance of a pump is characterized by its net head h, which is defined as the

change in Bernoulli head between the suction side and the delivery side of the pump. h

is expressed in equivalent column height of water.

RECIPROCATING PUMP or PISTON- PLUNGER Pump

The piston pump is one of the most common reciprocating pumps and, prior to the

development of high speed drivers which enhanced the popularity of centrifugals, it was

the pump of choice for a broad range of applications. Today , they are most often seen

in lower flow, moderate (to 2000 PSI) pressure applications. Its close cousin, the

plunger pump, is designed for higher pressures up to 30,000 PSI.

The major difference between the two is the method of sealing the cylinders. In a piston

pump the sealing system (rings, packing etc) is attached to the piston and moves with it

during its

stroke.

The sealing system for the plunger pump is stationary and the

plunger moves through it during its stroke.

Reciprocating pumps operate on the

principle that a solid will displace a

volume of liquid equal to its own

volume. The figure to the right is

that of a generic double acting

piston pump. If we were to remove

the two valves at the left hand side

of the figure and replace them with

an extension of the cylinder, we would have a single acting pump. The single acting

pump discharges water only on its forward stroke while the double cting pump

discharges on its return stroke as well. During the suction stroke (right to left) the ingle

acting pump’s discharge valve closes and allows fluid to enter the cylinder via the

suction valve. When the piston changes direction (reciprocates) the suction valve closes

and water is discharged through the discharge valve. In the double acting pump, the

same sequence occurs during both strokes and almost twice as much fluid is discharged

per unit time.

Reciprocating Pumps- classifications-construction and working of single acting and

double acting reciprocating pumps-plunger and piston pumps-discharge of a

reciprocating pump-theoretical power required- coefficient of discharge-slip-problems-

negative slip-indicator diagram-separation-air vessel (functions and working) Special

pumps-jet pump-Turbine pump-Submersible pump.

Piston or Bucket Pumps: Basic Principles

The most common and well-known form of displacement pump is the piston or "bucket" pump, a common example of which is illustrated in. These work by applying both the principles i.e., in the example of, water is sucked into the cylinder through a check valve on the up-stroke, and the piston valve is held closed by the weight of water above it; simultaneously, the water above the piston is propelled out of the pump as. On the down-stroke, the lower check valve is held closed by both its weight and water pressure, while the similar valve in the piston is forced open as the trapped water is displaced through the piston ready for the next up-stroke.

A typical traditional design of brass-lined cylinder borehole pump with a metal foot valve and a metal piston valve; the piston has two leather cup-washer seals(indicated on the diagram). The outer casing and end fittings are normally cast iron in a pump of this kind.

There are various basic relationships between the output or discharge rate (Q), piston diameter (d), stroke or length of piston travel (s), number of strokes per minute (n), and the volumetric efficiency, which is the percentage of the swept volume that is actually pumped per stroke (nVol)

Piston for use in Bore hole

Pistons and Valves

Type of seal, commonly used in single-acting bucket pumps, is the leather cup washer. Suitable grades of leather, commonly impregnated with "neatsfoot oil" boiled from the hooves of cattle, will function for surprisingly long periods (several years) in smooth drawn brass cylinders, or in smooth PVC. With the high cost of servicing deep boreholes, it is worth paying a premium to get a good life out of pump seals. Various synthetic leather "compound" materials based on plastics have been used for seals; these are often more consistent in their performance than leather and will often have bettor wear resistant characteristics.

Vertical section through a borehole pump (with extractable foot valve)

Hand pumps are manually operated pumps they use human power and mechanical

advantage to move fluids or air from one place to another. They are widely used in

every country in the world for a variety of industrial, marine, irrigation and leisure

activities. There are many different types of hand pump available, mainly

operating on a piston, diaphragm or rotary vane principle with a check valve on the

entry and exit ports to the chamber operating in opposing directions. Most hand pumps

have plungers or reciprocating pistons, and are positive displacement.

Types Suction and lift hand pumps

Suction and lift are important considerations when pumping fluids. Suction is the

vertical distance between the fluid to be pumped and the center of the pump, while lift

is the vertical distance between the pump and the delivery point. The depth from which

a hand pump will suck is limited by atmospheric pressure to an operating depth of less

than 7 meters. The height to which a hand pump will lift is governed by the ability of

the pump and the operator to lift the weight in the delivery pipe. Thus the same pump

and operator will be able to achieve a greater lift with a smaller diameter pipe than they

could with a larger diameter pipe.

Siphons Water will always try to find its lowest level. Using this principle, very simple pumps

with plastic or rubber bulb with flap valve at each end are used for emptying fuel or

water cans into tanks. Once the bulb is full the fluid will flow without further effort

from the higher to the lower container. Many hand pumps will allow the passage of

fluid through them in the direction of flow and diaphragm pumps are particularly good

at this. Thus where the levels are correct large volumes of liquid such as swimming

pools can be emptied with very little effort and no expensive energy use.

Direct action Direct action hand pumps have a pumping rod that is moved up and down, directly by

the user, discharging water. Direct action hand pumps are easy to install and maintain

but are limited to the maximum column of water a person can physically lift of up to

15 m.

Deep wells Deep well hand pumps are used for high lifts of more than 15 m. The weight of the

column of water is too great to be lifted directly and some form of mechanical

advantage system such as a lever or flywheel is used.

High lift pumps need to be stronger and sturdier to cope with the extra stresses. The

installation, maintenance and repair of deep well hand pumps is more complicated than

with other hand pumps. A deep well hand pump theoretically has no limit to which it

can extract water. In practice, the depth is limited

by the physical power a human being can exert in lifting the column of water, which is

around 80 m.

Diaphragm Diaphragm pumps have the advantage that they pump relatively lightly due to the lack

of pulling rods

and are corrosion resistant. Their disadvantage is that they need a specific length of

tubing and high quality

rubber diaphragms, which are costly and are relatively inefficient due to the extra work

needed to deform the

diaphragm.

Rubber diaphragms will eventually leak and need to be replaced. Because this is usually

complicated

and costly, diaphragm pumps operating in poor rural areas are often abandoned once the

diaphragm wears out.

Progressive cavity Progressive cavity pumps consist of a single helix rotor inserted into a double helix

stator. As the rotor

is turned, the voids in the stator are screwed upwards along the axis of rotation.

Progressive cavity pumps can

have complicated gearing mechanisms and are difficult for local pump technicians to

maintain and repair.

A rope and washer pump is a type of progressive cavity hand pump.

Range of lift

The range of lift of different types of hand pumps is given below:

Type Range

Suction pumps 0 – 7 meters

Low lift pumps 0 – 15 meters

Direct action pumps 0 – 15 meters

Intermediate lift pumps 0 – 25 meters

High lift pumps 0 – 45 meters, or more

MAJOR COMPONENTS USED IN PEDAL POWERED

WATER PUMP

1.Hand Pump

2. Pedal Arrangement- (Ball Bearings and Bi-Cycle pedals )

3. Rod

4. Ball valve

5. Pipe Fittings

6. Pressure Measuring gauges

7. Supporting frame

HAND PUMP :- Hand pumps are manually operated pumps; they use human

power and mechanical advantage to move fluids or air from one place to another.

They are widely used in every country in the world for a variety of industrial,

marine, irrigation and leisure activities.

Hand Pump

PEDAL ARRANGEMENT :-

This type link is used to connect the piston rod and foot step mechanism. This link is

very sturdy due it will withstand cyclic load.

Pedalling a modern stationary bicycle to produce electricity might be a great work-out,

but in many cases, it is not sustainable. While humans are rather inefficient engines

converting food into work, this is not the problem we want to address here; people have

to move in order to stay healthy, so we might as well use that energy to operate

machinery.

Pedal Arrangement

The trouble is that the present approach to pedal power results in highly inefficient

machines

ROD :-

It is connect the piston and foot pedal. It is also used push the piston according to the

foot pedal action. Rod is used to connect the piston and foot pedal pump link. The

maximum pressure is achieved pumping lifting height. It will convert angularity motion

to linear motion

.

Rod

Valve :-

Forged ball valve is used to start or stop the flow of water from

outlet port as desired

The main requirements of valves are a good seal when closed combined with lack of

resistance to flow when they are open, and rapid opening and closing while achieving

good durability. Usually rubber or alternatively precision ground metal mating surfaces

are necessary to ensure there are no leakage gaps when the valve is closed. Effective

sealing is particularly important with foot valves.

Pipe Fittings :-

Different pipe fittings are used ;-

1. 90° bend

2. Round Elbow

3. Straight normal pipe

4. Standard Tees

Pressure Measuring gauges:-

It is often convenient to express pressure in terms of the height of a column of

water, in meters or feet, instead of terms of psi or kPa. This is called pressure

head. Two Pressure measuring gauges are used i.e, for Suction and Exhaust

Delivery Pressure gauge

7. Supporting frame :-

It acts as base stand for the hand pump and supports all moving and non-moving parts

attatched the pump.

Suction Pressure gauge

ENERGY LOSSES IN PIPE FITTINGS

"When a fluid flows through a pipe line consisting of straight pipe and fittings, there is a

definite loss of pressure due to friction, This loss of head is often considerable and has

been investigated many times.

Various Pipe Fittings

Losses Due to Friction

The length of the pipe: The friction losses are cumulative as the water travels through

the length of pipe. The greater the distance, the greater the friction losses will be.

As water moves through the pumping system, pressure losses occur due to water contact

with pipes, valves, and fittings. The four factors that determine friction losses in pipe

are:

1. The velocity of the water: Water velocity is measured in feet per second. As

velocity increases, pressure losses increase. Velocity is directly related to flow rate. An

increase or decrease in flow rate will result in a corresponding increase or decrease in

velocity.

2. The size (inside diameter) of the pipe: Smaller pipe causes a greater proportion of

the water to be in contact with the pipe, which creates friction. Pipe size also affects

velocity. Given a constant flow rate, decreasing pipe size increases the water’s velocity,

which increases friction.

3. The roughness of the inside of the pipe: Pipe inside wall roughness is rated by a

“C” factor, which is provided by the manufacturer. The lower the C value, the rougher

the inside and the more pressure loss due to friction.

LOSSES IN VARIOUS PIPE FITTINGS

Losses due to friction

Losses due to Elevation change

Water pressure can be expressed as either “psi” (pounds of pressure per square inch) or

“feet of head.” A column of water 1 foot high exerts 0.433 psi at the bottom and

therefore 1 psi is equivalent to 2.31 feet of head. This means that for every foot of

elevation change from the pump to the discharge point, the corresponding change in

pressure will be 0.433 psi.

Fresh Water

Salt Water

1 foot of head = 0.433 psi 1 foot of head = 0.444 psi

1.0 psi = 2.31 feet of head 1.0 psi = 2.25 feet of head

Performance Terms and Definitions

Specifications Pumps are commonly rated by horsepower, flow rate, outlet pressure in feet (or metres)

of head, inlet suction in suction feet (or metres) of head. The head can be simplified as

the number of feet or metres the pump can raise or lower a column of water at

atmospheric pressure. From an initial design point of view, engineers often use a

quantity termed the specific speed to identify the most suitable pump type for a

particular combination of flow rate and head.

Pump material Pump material can be of Stainless steel ( SS 316 or SS 304) , cast iron etc. It depend

upon the application of pump. In water industry for pharma application, SS 316 is

normally used. As at high temperature stainless steel give better result.

Pumping power The power imparted into a fluid will increase the energy of the fluid per unit volume.

Thus the power relationship is between the conversion of the mechanical energy of the

pump mechanism and the fluid elements within the pump. In general, this is governed

by a series of simultaneous differential equations, known as the Navier-Stokes

equations.

However a more simple equation relating only the different energies in the fluid, known

as Bernoulli's equation can be used. Hence the power, P, required by the pump:

where ΔP is the change in total pressure between the inlet and outlet (in Pa), and Q, the

fluid flowrate is given in m^3/s. The total pressure may have gravitational, static

pressure and kinetic energy components; i.e. energy is distributed between change in the

fluid's gravitational potential energy (going up or down hill), change in velocity, or change in static pressure. η is the pump efficiency, and may be given by the manufacturer's information, such as in

Pump Capacity, Q = Volume of liquid delivered by pump per unit time,m/sec

Q is proportional to N, where N- rotational speed of the pump

Total developed head, H = The difference of discharge and suction pressure 99

Bureau of Energy Efficiency 3 /hr or m

The pump head represents the net work done on unit weights of a liquid in passing from

inlet of the pump to the discharge of the pump.

There are three heads in common use in pumps namely

(i) Static head

(ii) Velocity head

(iii) Friction head.

The frictional head in a system of pipes, valves and fittings varies as a function (roughly

as the square) of the capacity flow through the system.

System resistance: The sum of frictional head in resistance & total static head.

Pump Efficiency: Fluid power and useful work done by the pump divided by the power

input

in the pump shaft

Determination of Pump Efficiency

To determine pump efficiency, three key parameters are required: Flow, Head and

PowerOf these, flow measurement is the most crucial parameter as normally online flow

meters are

hardly available, in a majority of pumping system. The following methods outlined

below can

be adopted to measure the flow depending on the availability and site conditions.

Determination of total head, H Suction head (h)

This is taken from the pump inlet pressure gauge readings and the value to be converted

in to meters (1kg/cm

2 s = 10. m). If not the level difference between sump water level to the centerline

of the pump is to be measured. This gives the suction head in meters.

Discharge head (h)

This is taken from the pump discharge side pressure gauge. Installation of the pressure

gauged in the discharge side is a must, if not already available.

Troubleshooting Pump Problems

i. Pump Fails to Deliver Required Capacity

- air leaking into pump

- liquid cylinder valves, seats, piston packing, liner, rods or plungers worn

- pump not filling

- makeup in suction tank less than displacement of pump

- capacity of booster pump less than displacement of power pump

- vortex in supply tank

- one or more cylinders not pumping

- suction lift too great

- broken valve springs

- stuck foot valve

- pump valve stuck open

- clogged suction strainer

- relief, bypass, pressure valves leaking

- internal bypass in liquid cylinder

ii. Suction and/or Discharge Piping Vibrates

- piping too small and/or too long

- worn valves or seats

- piping inadequately supported

iii. Pump Vibrates

- gas in liquid

- pump not filling

- one or more cylinders not pumping

- excessive pump speed

- worn valves or seats

- broken valve springs

- loose piston or rod

- unloaded pump not in synchronism

- loose or worn bearings

- worn crossheads or guides

ACTUAL PROJECT

WORKSHOPS USED

Welding Shop

Fitting Shop

TOOLS USED

Pipe Wrenches

Adjustable Wrench

Open ended Spanners

Rasp files

Extra Materials Used

Plumbing thread

M-seal

Pipe fastening paste (Safeda)

Paint

TOTAL COST OF PROJECT

NAME OF

PRODUCT

QUANTITY COST

Hand pump 1 1200

Frame Material Hollow and Solid rods

of Different sizes

2000

Pipe Fittings

3 -> 90° Elbows,

Dia. -1”

250

5 -> Straight pipes,

Dia.- 1”

250

Brass Forged Ball

Valve

1 – Dia-1” 150

Pressure Gauges Suction

150

Delivery 150

Paint

1 litre

275

Other Expenses Transportation &

Assembly

3500

Total Seven Thousand Nine

Hundred Twenty Five

only

Rs. 7925/-

CONCLUSION

This modeling was centered towards the development of a hand pump by operating it

with help of Pedals that would conveniently alleviate the portable water supply

problems of rural communities throughout the underdeveloped and developing countries

of the world at minimum energy input. The requirement of Village Level Operation and

Management (VLOM) of maintenance was considered in the course of this modeling.

The model can be fabricated in the workshops as the design is made simple, while the

standard parts like bearings, bolts and nuts, etc., are readily available locally.

We have learnt alot from this project about types of tools, machines & how are they

used in mechanical workplaces in Industry, Some basic techniques like cutting, Surface

finishing, planning, grinding are introduced very nicely. In addition to this we have also

learnt about painting and welding. Moreover this project gave us a good experience of

purchasing material from market and increased our surveying capabilities

In the end I would like to thanks my teacher who guided us throughout the project

especially Mr. D.K. Soni .

It has been argued that current models of plunger pumps are inadequate in respect of the

complex interactions which take place between the pump and attached pipelines. These

arise because of the distributed parameter nature of the pipelines and because of

cavitation. A finite difference method for modelling pipelines, based on a Galerkin

method incorporating frequency-dependent friction, has been proposed. This approach

circumvents the computationally intensive demands associated with the use of the

method of characteristics.