THE DESIGN AND CONSTRUCTION OF A MANUALLY OPERATED

RECIPROCATING WATER PUMP

BY

AYOOLA OLANREWAJU DAVID.

(H/ME/12/0462)

SALAU SHERIF ALABI

(H/ME/12/0463)

OKEGBENRO RASHIDAT OLABISI. (H/ME/12/0464)

OLATILEWA QUADRI AJANI.

(H/ME/12/0466)

DEPARTMENT OF MECHANICAL ENGINEERING,

SCHOOL OF ENGINEERING.
THE FEDERAL POLYTECHNIC ILARO, OGUN STATE.

DECEMBER, 2014.

THE DESIGN AND CONSTRUCTION OF A MANUALLY OPERATED

RECIPROCATING WATER PUMP

BY

AYOOLA OLANREWAJU DAVID.

(H/ME/12/0462)

SALAU SHERIF ALABI

(H/ME/12/0463)

OKEGBENRO RASHIDAT OLABISI. (H/ME/12/0464)

OLATILEWA QUADRI AJANI.

(H/ME/12/0466)

A PROJECT SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR

THE AWARD OF HIGHER NATIONAL DIPLOMA IN THE DEPARTMENT OF
MECHANICAL ENGINEERING, SCHOOL OF ENGINEERING, THE FEDERAL
POLYTECHNIC ILARO.

DECEMBER, 2014.

CERTIFICATION
This is to certify that this project was carried out by Ayoola Olanrewaju, Salau Sherif,
Okegbenro Rashidat and Olatilewa Quadri under the supervision of Engr Osore, O.A and Mr
Adebesin, A.A in the department of mechanical engineering.

_____________________________
Supervisor's signature and date

_____________________________
Supervisor's signature and date

_______________________________
Head of department signature and date

DEDICATION
This project is dedicated to Almighty God. We also use this medium to appreciate our
beloved parents for their moral, spiritual and financial support for the completion of this
project mad also their support throughout our stay in school.

ACKNOWLEDGEMENT
We appreciate Almighty God who Has made the execution and completion of this project a
reality and for His unstoppable guidance over us. We appreciate the effort of our highly
experienced supervisor, Engr Olufemi A. Osore for his unlimited support and unreserved
advice during the course of this project.
Our profound gratitude also goes to Mr Adebesin, A.A.(supervisor ii) and all the lecturers
and workshops attendants in mechanical engineering department.
Finally, we are grateful to our parents, relations and friends throughout the completion of our
study and completion of this project.

ABSTRACT
This project is intended to provide an understanding of the fundamental principle of positive
displacement pump on the simple acting type. The head of the manually operated
reciprocating water pump is constructed from a 4mm gauge sheet metal to form a head of
380mm (length) by 230mm breath by 100mm (width). The pedestal is made by cutting a pipe
150mm diameter pipe of 4mm thickness to a length of 600mm.the water tank is constructed
from 156mm diameter pipe and welded to its base is a plate of 5mm thickness of 230mm
(length) by 189mm (breadth). The suction pipe which is a 75mm diameter pipe has a total
length of 3050mm is screwed to the water tank at its upper section and the lower diameter of
the suction pipe is screwed to the cylinder. In the cylinder is the plunger, foot valve, piston
seals, and discharge valves. The cylinder of which is lined with brass has a plunger rod
which is screwed to the connecting rod and a chain connects the collecting rod to the pump
handle enclosed in the pump head. The pump is of Indian mark III and mechanical advantage
is appreciably high.

TABLE OF CONTENT
Cover page
Title page

...

ii

iii

Dedication.

..

iv

Abstract.

..

Certification
Acknowledgement.

CHAPTER ONE
1.0 Introduction
1.1 Statement of problem.
1.2 Significant of the project.

1.3 Objective of the project.

1.4 Scope of the study.

CHAPTER TWO
2.0.

Literature review.

2.1.

Historical background.

2.2 .

Principles of lifting and moving water

2.3.

Classification of pumps

2.3.1.2 Division of positive displacement machines ..

2.3.1.3 Rotodynamic pumps

2.3.1 Positive displacement machines.

2.3.2. Types of positive displacement pumps

..

2.3.3. Types of rotodynamic pumps

..

11

2.3.4. Other types of pumps

..

12

2.4.

Power source for pumping and pumping efficiency. . 13

7

2.4.1. Power for pumping.

2.4.2. Pumping efficiency.

13

..

15

16

16

2.5.

Fundamental of hand pump.

2.6.

Causes of pressure loss in pipe.

2.7.

Materials used for water lifting devices ..

18

2.8.

Components parts

21

2.9.

Contribution of the project.

.. 23

CHAPTER THREE.
3.0. Methodology. ..

24

3.1. Project analysis and materials selection.

24

3.1.1 Cylinder.

25

3.1.2. Base plate.

.....

25

3.1.3. Pump head.

25

3.1.4. Head.

....

25

3.1.5. Discharge pipe.

......

25

..

26

3.1.6. Suction pipe and connecting rod.

3.1.7. Handle.

...... ...

26

3.2.

.....

26

Construction procedures.

3.2.1. Cutting.
3.2.2. Welding.
3.2.3. Drilling.
3.2.4. Filling/Grinding.
3.2.5. Bending.

......
............
..

26
27
27
27

..

27

3.2.6. Machining.

....

27

3.2.7. Finishing.

....

.27

3.3. Assembly procedures.

28

3.4. Process flow chart.

..

29

3.5. Bill of engineering materials.

.
8

32

CHAPTER FOUR.
4.0. Result and discussion.
4.1. Project test run.
4.2. Test run and result.
34

33

...

33
.

4.2.1. Percentage slip.

35

4.2.2. Volumetric efficiency and power input.

36

.
.

4.2.3. Reason why theoretical discharge is greater than actual discharge.

37
4.3.
37

Maintenance.

..

CHAPTER FIVE.
5.0. Conclusion and recommendations.
38
5.1. Conclusion.
38
5.2. Recommendations.
38

.
..
.

Reference
Appendix I
Appendix ii.

CHAPTER ONE
1.0

INTRODUCTION

The use of various machines and devices had been employed for ages to assist human beings
for various purposes. Simple machine has been age-long friend to human beings with
complex ones continuously derived from it. The core of this project is the design and
construction of a simple reciprocating water pump.
A reciprocating positive displacement pump is one in which a plunger or a piston displaces a
given volume of fluid for each stroke. The action of the pump causes 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 operation action, the action can either be can single acting that is
discharging once in a cycle or double acting that is discharging twice in a cycle.
Water is the basic need of life; our existence is in doubt in the absence of water. Scarcity of it
means life full of hardship and obstacle. This is a pitiful condition faced by many people in
rural hilly areas, especially in country like ours. Though we boast of being the richest in
water resources, but ironically water supply is our growing and burning problem. Owning to
this problem, a need of some simple, effective and affordable solution for water supply in
such areas can be found in the use of a reciprocating water pump.
There are many different ground water hand pumps, however many of these hand pumps are
positive displacement pump. This means they have reciprocating pistons or plungers. A
positive displacement reciprocating hand pump moves the water by trapping a fixed amount
of water to the outlet pipe. To understand how a hand pump works, one must first understand
the different components of the pump. The main components include, the operating rod (i.e.

10

piston or plungers) the glider, the piston valve and the foot valve or suction valve (Morgan,
1989).
1.1.

STATEMENT OF THE PROBLEM

The problem addressed in this project is the design and construction of a manually operated
reciprocating water pump so as to ensure water supply in the absence of electricity.
1.2.

SIGNIFICANCE OF THE PROJECT

The significance of this project is to develop a means of ensuring water supply. It ensures the
lifting of clean water for drinking and other purposes from depth up to 100meters and allows
the water source to be sealed, reducing the risk of potential source of contamination during
water collection. The pump can as well be used in places where access to water is scarce and
where financial resources for investment operations and maintenance are limited, thus
providing a cost effective solution to allow the countryside to gain access to clean water for
drinking and other purposes. Another significance of this project is to apply theoretical
knowledge into practical application thus optimizing resources and providing a reliable
source of water supply.
1.3.

OBJECTIVES OF THE PROJECT

The objectives of this project are as detailed below:

To carry out a literature review relating to manually operated reciprocating water

pump

To do a detailed geometrical analysis of the manually operated reciprocating water

pump and select suitable materials based on the analysis.

To prepare the working drawing for construction processes

To construct and test run the hand pump

11

To discuss the result of the test and determine the performance characteristic of the
proto-type constructed.

1.4

SCOPE OF THE STUDY

The scope of the study includes the followings:
i. Chapter one which contains introduction and objectives of the study
ii. Chapter two is a review of literature of material on topics relating to the project.
iii. Chapter three is a report on the fabrication processes and assembly of the project
iv. Chapter four is on the test run and discussion of the results based on observed data
and design consideration.
v. Chapter five is the conclusion and recommendations based on the findings from the
project.

12

CHAPTER TWO
2.0

LITERATURE REVIEW

This chapter is a review of literature in respect of some basic type of pumps and other
relevant topics, essentially the following topics are discussed

2.1

Historical background

Principles for lifting and moving water

Classification and types of pumps.

Power source for pumping and pumping efficiency.

Fundamentals of hand pumps

Causes of pressure losses in pump pipes.

Materials used for water lifting devices.

Component parts.

Contribution of the project.

HISTORICAL BACKGROUND

According to (Okuni 2005), water pumping technology developed in parallel with the source
of power available at the time, indeed one can say our first ancestors who cupped their hands
and lifted water from a stream chose the pumping techniques appropriate to them. Okuni
also described the availability of modern devices such as centrifugal pump which has reached
high state of development and widely used particularly in developed countries owing to the
availability of suitable power source such as diesel engine and electric motor.

13

Commenting on pumping, James and Gary (2008) wrote, although reciprocating pumps have
been around for over 2000 years, they did not gain wide popularity until 1940 when Henry R.
Worthington invested steam pump.
These early simple machines have evolved into the advanced reciprocating pumps seen today
in many industries. During the last thirty years, improvement in technology have allowed
centrifugal pumps and other types of pumps to become more popular.
Reciprocating machines are only limited to small applications, nevertheless, there are still
many applications where reciprocating pumps are still preferred. The dominance of these
alternative pump types had led to a knowledge gap for positive displacement machines,
however the positive displacement pump is still a vital part of industry and will remain in use
for foreseeable future.
2.2

PRINCIPLE FOR LIFTING AND MOVING WATER.

According to Peter (1997), some of the ways by which water could be lifted or moved,
include:
a. Direct lift
b. Displacement
c. Creating a velocity head
d. Using the buoyancy of gas
e. Gravity
a. Direct lift: This involves physical lifting of water in a container

14

b. Displacement: This involves utilizing the fact that water is (effectively)

incompressible and can therefore be pushed or displaced.
c. Creating a velocity head: When water is propelled to a high speed the momentum
can be used either to create a flow or to create a pressure.
d. Using the buoyancy of gas: Air (or other gas) bubble through water will lift a
proportion of the water.
e. Gravity: Water flows down under the influence of gravity.
2.3

CLASSIFICATIONS OF PUMPS

There are two types of hydraulic fluid machines, the positive displacement (or static machine)
and the rotodynamic machines. (Osore, 2013).
2.3.1

Positive displacement machines: These are machines which discharge or deliver a

fixed quantity of fluid to a specific machinery component as a result of pressure difference

P. The change in pressure is by displacement or reciprocating action and not by velocity or
kinetic change (Osore, 2013).
2.3.1.2

DIVISION OF POSITIVE DISPLACEMENT PUMP

Positive displacement pump can be divided into:

a. Single acting pump and
b. Double acting pump.
a. Single Acting Pump: This makes one delivery (discharge) per revolution (cycle), (i.e.
discharge in 2 strokes), in other words, a single acting pump discharges the cylinder volume
once in two strokes (Osore, 2013).

15

b. Double Acting Pump: This makes two deliveries (discharge) per revolution (2
strokes,360 ) of the crank in a cylinder that is (1 delivery per stroke). (Osore, 2013)

2.3.1.3

ROTODYNAMIC PUMP

A rotodynamic machine is one which there is a free passage of fluid between the inlet and
outlet through a rotating element called the impeller or runner and transfer energy as a result
of dynamic (velocity) or kinetic energy change. When energy is transferred from rotating
element to fluid the machine is called centrifugal pump and when energy is transferred from
fluid to rotating element, the machine is known as turbine. (Osore, 2013).
2.3.2

TYPES OF POSITIVE DISPLACEMENT PUMP.

A positive displacement pump can be classified according to the mechanism used to move the
fluid, there are various types of positive displacement pumps, but some of the commonly
available types are:
a. Rotary pump
b. Reciprocating pump
c. Progressive cavity pump
d. Peristaltic pump
e. Impulse pump (hydraulic ram Pump)
a. Rotary pump: A positive displacement rotary pump can be divided into three main
types namely:
i.

gear pumps,

ii.

screw pumps and

16

iii.
(i)

Moving vane pumps.

Gear Pumps: These are the simplest type of rotary pump consisting of two gear
laid out side by side with their teeth enmeshed. The gears turn away from each
other creating a current that traps fluids between the teeth of one gear and the
outer casing, eventually releasing the fluids on the discharge side of the pump as
the teeth mesh and go round again. Many small teeth maintain a constant flow of
fluid while fewer larger teeth create a tendency for the pump to discharge fluid in
short pulsing gush. (http://en.wikipedia.org/w/index.php?oldid=421515362)

(ii)

Screw Pumps: Screw pump are more complicated type of rotary pump, featuring
two or three screws with opposing thread, that is one screw turn clockwise and the
other counter clockwise. The screws are each mounted on shafts that runs parallel
to each other, the shafts also have gears on them that mesh with each other in
order to turn shaft together and keep everything in place. The turning of the
screws and consequently the shaft to which they are mounted, draws the fluid
through the pump. As with other forms of rotary pump, the clearance between
moving parts and pumps casing is minimal.

(http://en.wikipedia.org/w/index.php?title=pump&direction=next&oldid42151536
2)
(iii)

Moving Vane Pumps: Moving vane pumps are the third type of rotary pump
consisting of a cylindrical rotor encased in a similarly shaped housing. As the
rotor turns, the vanes trap fluid between the casings, drawing the fluid through the
pump. (http://en.wikipedia.org/w/index.php?oldid=421515362)

b. Reciprocating Pumps: Typical reciprocating pumps are the plunger or piston pump and
diaphragm pumps.

17

(i) Plunger Pump: A plunger pump consists of a cylinder with a reciprocating plunger in it.
The suction and discharge valves are mounted in the head of the cylinder. In the suction
stroke the plunger retracts and the suction valve opens causing suction of fluid into the
cylinder. In the forward stroke, the plunger pushes the liquid out of the discharge valve with
only one cylinder, the fluid flow varies between maximum flow when the plunger moves
through the middle position and zero flow when the plunger is at the end positions. A lot of
energy is wasted when the fluid is accelerated in the piping system. Vibration and water
hammer may be a serious problem. In general the problems are compensated by using two
or more cylinders not working in phase with each other.
(http://en.wikipedia.org/w/index.php?oldid=421515362)
(ii) Diaphragm Pump: An alternative to the use of a piston in a cylinder for pumping is to fit
one wall of a pump chamber with a flexible diaphragm which when moved in and out
displaces water. The left hand valve is analogous to the foot valve of a piston pump and the
right hand valve is to the delivery one (Peter, 1997).
In diaphragm pumps, the plunger pressurizes hydraulic oil which is used to flex a diaphragm
in the piping cylinder. Diaphragm valves are used to pump hazardous and toxic fluids.
(http://en.wikipedia.org/w/index.php?oldid=421515362)
c. Progressive Cavity Pump: The progressive cavity also known as progressing cavity or
mono pump (named after its French inventor, Manteaux) is unique. It is commercially
available as a rotary positive displacement pump that readily fits into bore holes. (Peter
1997). The progressive cavity pump is widely used for pumping difficult materials such as
sewage sludge contaminated with large particles. The pump consists of a helical shaped
rotating shaft, about ten times as long as its width. This shaft fits inside a heavy duty rubber
sleeve. As the shaft rotates, fluid is gradually forced up the rubber sleeve. Such pumps can
develop very high pressure at quite low volume.

18

(http://en.wikipedia.org/w/index.php?oldid=421515362)
d. Peristaltic Pumps: A peristaltic pump is a type of positive displacement pump used for
pumping a variety of fluids. The fluid is contained within a flexible tube fitted inside a
circular pump casing (though linear peristaltic pumps have been made). A rotor with a
number of rollers, shoes or wipers attached to the external circumference compresses the
flexible tube. As the rotor turns, the part of the tube under compression closes (or occludes)
this forcing the fluid to be pumped to move through the tube. Additionally, as the tube opens
to its natural state after the passing of the cam (restitution) fluid flow is induced to the pump.
This process is called peristalsis and is used in many biological systems such as the
gastrointestinal tract.
(http://en.wikipedia.org/w/index.php?oldid=421515362)
e. Impulse Pumps (Hydraulic ram pumps): Impulse pumps (hydraulic ram pumps):
hydraulic ram is a water pump powered by hydropower. It functions as a hydraulic
transformer that takes in water at one hydraulic head (pressure) and flow-rate, and delivers
water at a higher hydraulic-head and lower flow rate. The device utilizes the water hammer
effect to develop pressure that allows a portion of the input water that powers the pump to be
lifted to a point higher than where the water originally started. The hydraulic ram is
sometimes used in remote areas where there is both a source of low-head hydropower and
need for pumping water to a destination higher in elevation than the source. In this situation,
the ram is often useful, since it requires no outside source of power than the kinetic energy of
flowing water.
(http://en.wikipedia.org/w/index.php?oldid=421515362)

19

2.3.3

TYPES OF ROTODYNAMIC PUMPS

The followings are the types of rotodynamic pumps

a. Centrifugal pump
b. Radial flow pump
b.

Axial flow pump

c.

Mixed flow pump

a. Centrifugal Pump: A centrifugal pump is a rotodynamic pump that uses rotating impeller
to increase the pressure of flow rate of a fluid. Centrifugal pumps are the most common type
of pumps used to move liquid through a piping system. The fluid enters the pump impeller
along or near to the rotating axis and is accelerated by the impeller, flowing radially outward
or axially into a diffuser or volute chamber from where it exists into the downstream piping
system. They are typically used for large discharge through smaller heads. They are as well
mostly associated with radial flow type. However the term centrifugal pump can be used to
describe all impeller type rotodynamic pump including the radial axial and mixed flow
variations. (http://en.wikipedia.org/w/index.php?oldid=421515362).
b. Radial Flow Pumps: Radial flow pumps often simply refer to as centrifugal pumps. The
fluid enters along the axial plane, is accelerated by the impeller and exist at right angles to
shaft [radially]. Radial flow pump operates at higher pressure and lower flow rate than mixed
or axial flow pump. (http://en.wikipedia.org/w/index.php?oldid=421515362).
c. Axial Flow Pumps: Axial flow pump; this pump differ from radial flow in that the fluid
enters and exists along the same direction parallel to the rotating shaft. The fluid is not

20

accelerated but instead lifted by the action of the impeller. They may be likened to a propeller
spinning in a length of tube. Axial flow pump operates at much lower pressure and higher
flow rates than radial flow pumps. (http://en.wikipedia.org/w/index.php?oldid=421515362).
d. Mixed Flow Pumps: Mixed flow pumps; as the name suggests, function as a compromise
between radial and axial flow pumps. The fluid experiences both radial acceleration and lift,
and exists the impeller somewhere between 0-90 degrees from the axial direction. As a
consequence, mixed flow pump operates at a higher pressure than axial flow pump while
delivering higher discharge than radial flow pumps. The exist angle of the flow dictates the
pressure head-discharge characteristics in relation to radial and mixed flow.
(http://en.wikipedia.org/w/index.php?oldid=421515362).
2.3.4 Other types of pumps are:
a. gravity pump and
b. steam pump
a. Gravity pump includes the Syphon and Herons fountain and as well as important system
such as qanat or foggara system (a water pumping system developed by the Persian people)
which simply use downhill flow to take water from far underground aquifers in high areas to
consumers at lower elevation. The hydraulic ram is also sometimes refers to as gravity pump.
b. Steam pumps: Steam pumps are now mainly of historical interest. They include any type
of pump powered by a steam engine and also piston less pump such as Thomas Saverys
pump and the pulsometer steam pump.
(http://en.wikipedia.org/w/index.php?oldid=421515362).

21

2.4

POWER SOURCE FOR PUMPING AND PUMPING EFFICIENCY.

There are different power sources for pumping and each source is made use of according to
its availability. Patrick (2005) wrote, for small community in developing country, human and
animal power is often the most readily available power for pumping water particularly in
rural areas. Solar energy can as well be of potentials. Diesel engine should only be used if
fuel is available and electric motor if electricity supply is reliably available together with
adequate maintenance and spare parts.
2.4.1

POWER FOR PUMPING

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 element within the pump. In general, this is governed by a series of
simulation differential equation known as the Navier-stokes equation, and is given by
(

+ .

Where:

)=

+ . T + f.

V is the velocity of flow

is the density of fluid
P is the pressure
T is the stress deviator tensor (deviatoric) component of the total stress tensor, which has
order two,
f represent the body force (per unit volume ) acting on the fluid,
is the del operator.

22

This is the statement of the conservation of momentum in a fluid and it is the application of
Newtons second law of continuum. This equation is applicable to any non- relativistic
continuum and also known as Cauchy momentum equation.
However a more simple equation relating only the different energies in the fluid, known as
Bernoullis equation can be used. It is given by

&

&

: Pressure in the inlet and discharge pipe

: velocities in the inlet and discharge pipe

& are the reference level.

Hence the power P, required by the pump is given by
P=

Where P is the change in total pressure between the inlet and the outlet (in PA).
Q is the fluid flow rate in m3/S.

The total pressure may have gravitational, static pressure and kinetic energy component that
is energy is distributed between change in fluids gravitational potential energy (going up or
down hill), change in velocity or change in static pressure.
Is the pump efficiency and may be given by the manufacturers information, such as in the
form of a pump curve and is typically derived from either the dynamic simulation (i.e.
solutions to the Navier-strokes for the particular pump geometry), or by testing. The
efficiency of the pump will depend upon the pumps configuration and operating conditions,
such as (rotational speed, fluid density and viscosity).
For a typical pumping configuration, the work is imparted in the fluid and thus positive. For
the fluid imparting the work on the pump, (i.e. a turbine), the work is negative, power
23

required to drive the pump is determined by dividing the output power by the pump
efficiency. Further-more, this definition encompasses pumps with no moving parts such as a
siphon. (http://en.wikipedia.org/w/index.php?oldid=421515362).

2.4.2

PUMPING EFFICIENCY ( )

Pump efficiency is defined as the ratio of the power imparted on the fluid by the pump in
relation to the power supplied due to the pump. Its value is not fixed for a given pump,
efficiency is a function of the discharge and also the operating head. For centrifugal pump,
the efficiency tends to increase with flow rate up to a point midway through the operating
range (peak efficiency) and declines as flow rate rises further. Pump performance data such
as this is usually supplied by the manufacturer before pump selection. Pump efficiencies tend
to decline over time due to the wear (e.g. increasing clearances as impeller reduces in size).
. =

One important part of system design involves matching the pipeline head loss-flow
characteristic with the appropriate pump or pumps which will operate at or close to the point
of maximum efficiency. There are tools that help calculate the head needed and show pump
curves including their best efficiencies point (BEP). Pump efficiency is an important aspect
of pump that should be regularly tested. Pump selection is done by using a performance curve
drawn from the pressure heads and flow rates, and also power supply is taken care of. Pumps
that are normally available runs at 50 Hz or 60 Hz.
(http://en.wikipedia.org/w/index.php?oldid=421515362).

24

2.5 FUNDAMENTALS OF HAND PUMP

Hand pump operates on the principle of fluid mechanics. Mechanical energy is used to lift the
water from some depth below ground to the surface, and the water is moved by taking
advantages of the pressure difference. The fluid moves from an area of higher pressure to a
lower pressure when the piston is moved up and down. When the piston moves upward, there
is a decrease in pressure within the cylinder; this causes the water to flow into the cylinder
through the foot valve, when the piston moves down, the water is forced downward,
increasing the pressure, and the foot valve closes, the piston valve opens and the high
pressure water exits through the outlet pipe. Therefore the pressure within the cylinder
automatically controls the operation of the foot valve.

2.6 CAUSES OF PRESSURE LOSSES IN PUMP PIPES

Osore (2013), identified three major losses in pump pipe as follows,
1
2
3

Friction loss

shock loss, and

Fittings/valve loss,

(1) Friction loss, occurs between the moving particles of fluids and the interior surface
(rough) of the pipe, it is given by:
.

For turbulent flow,

.

f=
.

While for laminar flow,

25

Where:
: is head loss due to friction,
L: is length of pipe,

Q: is the discharge,
f : is the friction factor
d: is the diameter of the pipe, g is acceleration due to gravity.
(2) Shock losses, are due to sudden enlargement or contraction of flow within the crosssectional area. It is given by
=(1

Where:

) .

: is the area of the inlet pipe and

: is the area of the discharge pipe.
(3) Fittings/valve losses, : Fittings and valve losses are due to bends (elbows), valve, and
entrance to and exist from pipes. Losses due to shock, fittings and valve are usually
considered as minor losses, head loss due to entry is given by:

Head loss due to exit is given by

, Where:

: is the velocity in the inlet pipe,

: is the velocity of liquid in the discharge pipe.

The total head loss, in the pipe is given by

= + +

26

2.7

MATERIALS USED FOR WATER LIFTING DEVICES

Four main considerations apply for construction materials used for pumping water. These
according to Peter (1997) include:
a. Strength-Stressed components need to be able to function over a long period of time
without failing either through over-load or more likely through fatigue.
b.

Corrosion resistance and general ability to co-exist under wet condition.

c. Resistance to wear and abrasion is important for components that rub or slide, or parts
which are in contact with flowing water if any particular matter is likely to be
suspended in the water.
d. Cost
The following are the materials used for the pump construction
(a) Ferrous metal
(b) Non-ferrous metal
(c) Plastic
(d) Timber
(a) Ferrous Metal: Most ferrous iron based materials are subject to corrosion problem, but
to compensate for this limitation, they are electroplated with corrosion resistant materials
such as copper and zinc, they are perhaps the most familiar low-cost, strong material that are
widely available. Generally, iron or steel materials are best suited for use in structural
components where strength is important and surface coating of rust will not cause serious
problem (Peter, 1997). Other focus or types of ferrous metals are cast-iron, wrought iron, pig
iron and steel (Ajibola, 2014).

27

(b) Non Ferrous Metals: Brass (a copper-zinc alloy) is commonly used for reciprocating
pump cylinders. Due to its high cost, thin seamless, brass tube is often used only as a cylinder
inner inside a steel casing instead of a thick brass cylinder. Brass has good wear resistance in
rubbing situation that is with a leather piston seal but not particularly strong metal structurally
especially in tension. An alternative is the use of admiralty brass which contains a small
percentage of tin which generally improves its corrosion resistance (Peter, 1997). Other nonferrous materials are bronze, aluminum, zinc, and their alloys (Ajibola, 2014).
(c) Plastic: There is a large and growing family of plastics which broadly includes three main
categories namely:
i.

Thermoplastics

ii.

Thermosetting

iii.

Resin

i.

Thermoplastic: These are plastics which soften with heat can therefore readily be
heated and worked, molded or extruded.

Thermoplastics based on polymerized petrochemical are generally the cheapest plastics, those
used in irrigation context include
v PVC (Polyvinylchloride)
v High density polythene
v Polypropylene (Peter, 1997)
PVC (Polyvinylchloride) is commonly used for extruded pipes, it can be rigid or plasticized
(flexible). It is important to note that only certain grades of PVC (and other plastics) are
suitable for pipes to convey drinking water for people or livestock, since traces of toxic
plasticizer can be present in the water passed through some grades. PVC is relatively cheap

28

and durable, but it is subject to attack by the UV (Ultra-Violet) wave length in sun-light and
should therefore be buried to protect it from the sun, or painted with a suitable finish to
prevent surface penetration by UV radiation. PVC is a thermoplastic and therefore softens
radiation. PVC is a thermoplastic and therefore softens significantly if heated above 800c, this
is not normally a problem in wet application but it is if pipes are left empty of water in hot
conditions (Peter, 1997)
ii.

Thermosetting: Thermoset plastics contain polymers that cross-link together

during the curing process to form an irreversible chemical bond. The cross-linking
process eliminates the risk of the product re-melting when heat is applied, making
thermosets ideal for high-heat applications such as electronics and appliances.
Thermoset plastics significantly improve the materials mechanical properties,
providing enhance chemical resistance, heat resistance and structural integrity.
Thermoset plastics are often used for sealed products due to their resistance to
deformation. (Peter, 1997)

iii.

Resin: This plastics is softer and weaker than metal but suitable for combating
corrosion than metals. (Peter, 1997)

(d) Timber: Timbers exist in a very wide variety of types, their densities can range from
around 500kg/m3 (or less) up to 1300kg/m3. They also offer a very large variation in
mechanical properties, workability, wear resistance and behavior in wet condition. Timber is
also susceptible to damage by insect, fungus or fire (Peter, 1997). The most durable timbers
are generally tropical hard woods such as green heart, Iroko, Jerah, Opepe, Teak and
wallabies. The durability of many timbers can be improved by treating them with various
types of preservatives; the most effective treatment involves pressure impregnation with
either tar or water based preservatives (Peter, 1997)

29

2.8

COMPONENT PARTS

(a) Piston seal: Many properties are required of the piston seal. It should not be toxic (i.e.
should be non-toxic), long lasting, low friction, resistance to mildew, fungi, and other
biological attacks should be readily available, flexible enough to fill cylinder regulation but
rigid enough to avoid being turned inside out, and resistance to cycle wetting and drying.
Leather molded into a cup is the most popular piston seal material. The quality of a leather
cup seal can vary quite a lot, depending on the quality of leather used. The optimal is 4-5mm
thick of the type used by shoemakers or saddle makers. Traditionally tanned leather wears out
fast because the tanning process uses lots of salts and they become waterlogged and soggy in
the pump. Other polymer based materials may be used for piston seal and they require close
tolerance in the pump chamber, possible materials include rubber, neoprene, and epoxy or
elastomeric filled fabric (Peter, 1997).
Packings may also be used as piston seals, but they must be compressed to a very precise
amount to get the right balance between wear and sealing, graphite asbestos was traditionally
used as a packing materials but graphed PTEE offers superior sealing and wear. Braided
hemp and canvas are also used as packing materials. Slow seepage of water through only one
seal is used to cool and lubricate it. Typically, only one seal is used on a piston, for well
deeper than 30m and is common to additional seal for every 15m of depth (Peter, 1997).
(b) Cylinder: The internal surface finish of the cylinder is critical to getting acceptable piston
seal wear. Plain steel pipe is smoother than iron but experience has shown that it does not
perform as well, possibly because it has more peak deviation and they do not wear down so
quickly. PVC has exceptional smoothness, but it can easily become scoured by silt and solid
impurities due to its softness, more so, the secret of long piston cup life is smoothness of
cylinder. PVC cylinder may be fitted with a brass sleeve, as both of these materials are

30

exceptionally smooth. When the liner is used, it is inserted into the PVC and the PVC is
heated until it shrinks slightly, holding the liner securely in place. (Carl and Hugh, 1995).
The main consideration when choosing a material are its strength in overload and fatigue,
corrosion resistance, wear and abrasion resistance for parts sliding against each other or in
contact with particulate matter suspended in water and cost. All these are given consideration
in the methods used in designing the projects.
Non-ferrous metals such as brass, which has a good resistance in rubbing situation are often
used for cylinders. Brass is not very strong, and has a high cost, so often a thin brass liner is
used in steel cylinder. Admiralty brass has a small amount of tin added to improve corrosion
resistance.
(c) Actuator Bearing: Findings indicates that (15.6mm) diameter by (37.5mm) long bearing
surfaces are minimal. Bearing surface should be made with as close tolerance as possible to
ensure longer life. The life expectancy of a bearing should be 9-12 months. The dry bearing
solution uses acetal, Copolymer a strong dimensional stable water resistance material that is
easy to mold (Robert, 1990)
(d) Valves: The pump valve is its most critical component. They are typically sized so that
water moving through them does not exceed a certain velocity. For suction valve, 0.9-2.4m/s
and for discharge valve, 1.8-6m/s. The cross sectional area through which the water flows is
known to be the split area. Findings indicate that the suction (foot) valve should have a port
area 2/3 of the piston area and discharge (piston) valve should have a port area of piston
area. Other sources recommended that the port opening be 40-50% of the cylinder crosssectional area.
However, for slow running hand pump, it has been determined experimentally that a port area
of 15% is adequate and larger port area does not improve mechanical efficiency by much.
Valves are typically some form of rigid object which is constrained to travel vertically down

31

onto the valve plate and backed by a spring to help them close properly. Two things prevent
pump at normal operating speed from attaining the theoretical performance. First, valve often
accelerates faster than the piston, requiring it to pause slightly for the piston to catch up.
Second, the valve is delayed in opening due to inertial and valve striction force and striction
is caused partly by cohesive forces between valve and it seat and also by the theoretical
pressure drop that occurs when water flow radially outward from under the valve flap.
Whatever the valve arrangement, the main criteria for a valve are that it maintains a tight seal
when closed and little-flow resistance when open. Valve and piston are made from
aluminum, copper alloy such as gunmetal, stainless steel, or injection molded plastic.
Corfam is also used for pump cups and nylon fabric coated with neoprene is used for valve
flaps. These materials give much better wear and strength than the all PVC pump, but they
are much more expensive. (Robert, 1990).

2.9

CONTRIBUTION OF THE PROJECT

Although reciprocating pump has been in existence for long but some challenges still persist.
Therefore, this project was embarked on so as to ensure durability of manually operated
reciprocating pump, tackling the problem of seal wear by the use of rubber seals instead of
fiber seals as in the common types.

32

CHAPTER THREE
3.0

METHODOLOGY

This chapter discusses the details of the methods, procedures and production processes
employed for the design and construction of a manually operated reciprocating water pump.
Essentially, the following topics are covered.
(i)

Project analysis and material selection

(ii)

Construction procedures

(iii) Process flow chat.

(iv) Bill of engineering materials
3.1

PROJECT ANALYSIS AND MATERIALS SELECTION

The materials to be used for the construction of a manually operated reciprocating water
pump are exposed to water, therefore the materials that should be rigid, strong and corrosive
resistance. The major material used is galvanized mild steel which is ductile and rigid. The
word galvanized means it has been coated with zinc which is corrosive resistance. Other
corrosion resistance materials such as brass, rubber seals and rubber raiser pipe (suction pipe)
are considered so as to tackle the problem of corrosion since the materials are always in
contact with water. Cylinder made of cast iron lined internally with brass is considered. The
materials for the various parts of the pump are discussed thus:

33

3.1.1 Cylinder
The cylinder is made from cast-iron to withstand high pressure and compressive force during
water collection (water lifting).Its resistance for oxidation and destruction by weakening
makes it a preferred choice while brass is used as internal lining because of its high resistance
to corrosion. The foot valve, discharge valve and plunger are all made of brass which is
corrosion resistance and the plunger seal is made of rubber for longevity.
3.1.2 Base Plate
Galvanized mild steel is used for the base plate. Although wrought iron is generally more
corrosive than mild steel but mild steel is used because it is readily available, easily
fabricated and reasonably cheap. The 5mm thick water tank base plat is cut to 230mm by
189mm, the material is used because of its strength and can withstand the weight of the head.
3.1.3 Pump Stand
This is otherwise called pedestal. This pipe is made of galvanized mild steel. The 156mm
diameter pipe is cut to a length of 600mm and it carries the water tank and head.
3.1.4 Head
The head is made of galvanized plate metal (mild steel). It consists of inspection cover, and
the handle. The head is mounted on the water tank. The thickness of the plate metal is 2mm
and flame cut to 380 by 230mm.
3.1.5 Discharge Pipe
This is a 50mm diameter pipe with a thickness of 4mm. It is made of galvanized mild steel
and cut to a total length of 410mm.

34

3.1.6 Suction Pipe and Connecting Rod

The suction pipe has a length of 3050mm (10.3 ft) while the connecting rod has a length of
3150mm (10.5 ft). The suction pipe is a rubber material while the connecting rod is of brass.
3.1.7 Handle
During the operation of the pump, the handle may be subjected to impact and sudden load
(force), therefore more rigid material is employed. Other factors considered for the selection
or choice of a pump handle are:
(i)

Good resistance to water and chemical attack.

(ii) Resistance to scratch.

3.2

CONSTRUCTION PROCEDURES

In this section, the fabrication and production processes employed in the construction are
discussed. These processes includes:
(i)Cutting

(ii) Welding

(iii) Drilling (iv) Filing/grinding (v) Bending (vi) Machining

vii) Finishing
Appendix I is the working drawing for these processes.
3.2.1 Cutting
The sheet metal (mild steel) was measured and cut to the required size of the head of 380mm
(length) and 230mm (breadth) using oxyacetylene cutting process (flame cutting). The
pedestal upper plate and water tank base plate were flame cut to 230mm (length) and 189mm
(breadth). The discharge pipe which is of 2mm thickness was cut into (280 by 130mm) using
a hack saw. The water tank which has a diameter of 156mm was cut to a length of 200mm
while the casing (pedestal) was cut to a length of 600mm using a hack saw.
35

3.2.2

Welding

Four sheet metals of thickness 380 by 230mm and 300 by 100mm were welded together to
form the head. The base plate of length 280mm and breadth 189mm was welded to the tank.
The stands (angle iron) were also welded to the pedestal (casing).
3.2.3

Drilling

Holes of 14mm diameter were drilled on the sheet metals welded to the base and top of the
water tank, the plate welded to the top of the pedestal pipe and the plate welded to the head
base using the pillar drilling machine.
3.2.4 Filing/Grinding
Filling and grinding of the welded surface were done using files and grinding machine to
provide a smooth surface finish
3.2.5 Bending
The head cover is of a 2mm thick sheet metal plate and was bent into the required shape by
means of a bending machine.
3.2.6 Machining
Machining operation was carried out on the stainless rod to form the key which connects, the
chain, the connecting rod & handle together in the head.
3.2.7 Finishing
At the end of the production, the assembled parts was wire brushed to remove oxide coating
due to reaction which might not allow the paint to stick to it and the pump was finally
painted.

36

3.3

ASSEMBLY PROCEDURE

The assembly of the pump starts by connecting the connecting rod to the plunger rod. The
selection pipe is screwed to the cylinder while it passes through the pedestal pipe. The water
tank is mounted on the pedestal. The bearing handle is keyed to the head which is placed on
the water tank. The pump connecting rod is connected to the handle by a chain both of which
are hidden in the pump head. (Appendix II is the assembly drawing for the pump).

37

3.4
S/N

PROCESS FLOW CHAT

Components

Machine Tool Used

Operations

Dimension of

Material

Performed

parts (mm)

type

230 x 189

Water tank

Surface grinding, arc

Flame cutting,

base plate

welding machine and

welding, grinding and

oxyacetylene

drilling

Functions

Remarks

Galvanized

To ensure the

Constructed

mild steel

mounting of the
water tank on the

grinding device
2

Head

Surface grinding, arc

pedestal
Flame cutting,

380 x 230

welding machine, and welding, grinding and

oxyacetylene welding

Galvanized

To ensure the

mild steel

housing of the
handle, connecting

drilling

device
3

Constructed

rod and bearing.

Pump

Indian mark

To lift the water

iii

through the suction

pipe and displaced

38

Purchased

by the discharge
pipe
4

Pedestal

Hack saw, welding

Cutting, welding,

156 by a

Mild steel

To house the raiser

machine, grinding

grinding

length of 600

galvanized

or suction pipe and

machine
5

Constructed

to stand the head

To actuate the

Handle

Purchased

reciprocating action
of the pump
6

Discharge

Hack saw, welding

pipe

machine

Cutting, welding

230 x130

Galvanize

To ensure the

mild steel

gushing of fluid

Constructed

pumped into a
receiver
7

Stand

Hack saw, arc

Cutting, welding

50

Mild steel

To stand the casing

carrying the tank

39

Constructed

welding machine
8

Key

Power hack saw,

and head
Cutting measuring

caliper, lathe machine and machining

40

Stainless

To key the handle

steel

bearing to the head

Constructed

3.5

BILL OF ENGINEERING MATERIALS

S/N MATERIAL

QUANTITY

AMOUNT (N)

Pump (Indian Mark III and connecting

1 Pump with 10 connecting

28,000

rod

rods

Mild Steel Plate (4mm Gauge)

length

2,000

Mild steel pipe (50)

length

1,000

Mild steel pipe (156)

length

2,500

Electrode

pack

600

Mild Steel Plate (5mm Gauge)

length

2,100

7.

Suction pipe

3,500

Bolts and nuts

525

Handle and chain

1 each

2,500

10

Stainless rod

length

1,400

11

Transportation

9000

TOTAL

N53,125

41

CHAPTER FOUR
4.0

RESULTS AND DISCUSSION

The design and fabrication processes employed in the course of constructing the manually
operated reciprocating water pump are critically analyzed so as to produce a project that will
meet up to expectation in terms of functionability, efficiency and maintenance.
The cylinder is of simple configuration and very rigid to withstand the reciprocating action of
the piston as well as vibration during usage. It incorporates a special type of seal (rubber seal)
which prevents vacuum in the cylinder thus increasing the pumping efficiency.
The suction pipe is made of rubber so as to increase resistance to wear/abrasion while the
discharge pipe is made of galvanized mild steel which has favorable resistance to corrosion.
The head, water tank, base plates and the pedestal or casing are all made of galvanized mild
steel. The casing pipe or pedestal is of 600mm in height which is assumed to be the average
height of humans thus enhancing easy handling while pumping.

4.1

PROJECT TEST RUN

The use of the manually operated reciprocating water pump reveals that the time taken for
discharge to occur will vary depending on the human power employed. Within certain limit,
heart beat and respiration show a linear relationship with energy expenditure or work input.
The heart beat is readily measured through the pulse rate of about 30 beats per minute above
the resting pulse rate which is the optimum limit of performance for long term pumping.

42

Different results were obtained regarding the time taken to lift the water from a depth of
about 3300mm. Different ages of human being were used to obtain these result.

4.2

TEST RUN RESULT

Age of Man
23 Years

Time Taken(s)
(t)
41

25 Years

39

39

26 Years

42

40

24 Years

45

42

The theoretical discharge is given by:

Q=
A=

Where;
A =Area of piston
L=Length of stroke = 230mm (0.23m) = constant
t =Time taken in seconds(s)
n =Number of strokes
d= diameter of the plunger = 60mm (0.06m) = constant
Length of Stroke to be 230mm (0.23m)
Area of piston=

= 0.002828

The actual discharge is given by:

Q =

Where
V= volume of water=10litre (constant)
t=time taken
43

Number of stroke
(n)
39

Calculation of theoretical discharge Q and actual discharge Q

Age of man

Time taken
t(s)

Number of
strokes (n)

23 years

41

39

0.0003095

25 years

39

39

0.00032521

0.0002564

26 years

42

40

0.00030973

0.0002381

24 years

45

42

0.00030353

0.0002222

The average theoretical discharge: Q

=

= 0.00031195
The average actual discharge :
=
=

= 0.00024015

4.2.1

Percentage slip

The percentage slip of the pump is given by:

% slip = [
=

] x 100
.

100

44

Theoretical
discharge
Q=

Actual discharge
Q =
0.0002439

100

= 0.2301 100

= 23.01%

4.2.2 Volumetric efficiency () and power input.

The volumetric efficiency which is also the coefficient of discharge (
=
=

100

) is given by:

100

= 0.7698 100

= 76.98%

Given the following parameters

Density, = 1000
Acceleration due to gravity, g= 9.81
Actual discharge Qa= 0.00024015
Total head, H = ( + ) = 35

+ 3460

= 3495mm = 3.5m.

Therefore the power output is given by

P = g

= 1000 9.810.000240153.5
= 8.2455W

The overall efficiency is given by

=
Assuming an overall efficiency of 72%, the power input is therefore given by
=

= 8.2455/0.72
45

= 11.4521W

4.2.3 Reasons why Theoretical Discharge (Q) is Greater than the Actual Discharge (Qa)
1. Leakage through the valves, piston packing or seals.
2. Partial filling of the cylinder.
3. Imperfect operation of the valves.

4.3

MAINTENANCE

The piston seal of manually operated reciprocating water pump is subjected to wear and tear,
therefore, proper maintenance needs to be employed. Selection of quality materials for the
design of the pump is necessary so as to stand the test of time.
The following failure modes are the most common in hand pumps.
(i)

Wear of handle bearing pivot pin key

(ii)

Breakage of handle and breakage of nuts and bolts.

(iii)

Wear of piston cups.

(iv)

Valve and seal problems.

The following maintenance procedure can however be employed.

(i)

Do sweep the platform regularly.

(ii)

Compost should be made far from the pump.

(iii)

The pump should be stroke gently.

(iv)

The pump handle should be pump with long slow stroke.

(v)

Rubbish should not be allowed to gather near the pump.

(vi)

Always ensure that the platform is made dry.

46

CHAPTER FIVE

5.0

CONCLUSION AND RECOMMENDATION

In this chapter, the final discussion on the designed project and possible recommendation to
improve the design are analyzed.

5.1

CONCLUSION

The process of designing and construction of manually operated reciprocating water pump
exposed us to the concept of designing and how to select suitable materials and choice of
construction method for a particular project.
The primary purpose of this project is to pump water from a depth of 3300mm. This was
achieved, thereby giving a volumetric of 77% with 23% as percentage slip. An average
human being can pump water effectively by applying a power input of 11.45W.

5.2

RECOMMENDATION

After the project has been designed and constructed and having carried out all the necessary
drawings and write-ups, we therefore recommend that:
- Materials like galvanized mild steel should be employed for the construction of
the head, pedestal, water tank and discharge pipe because of toughness and
resistance to corrosion.

47

- The cylinder to be used must be made of cast-iron which has high resistance to
compressive and impact load and to be lined internally with brass which has
high resistance to water and oxidation.
- The handle should be made of material that is strong and rigid to withstand
impact load/force during usage.
- Rubber seal should be employed instead of fiber seal which soaks and expands
when wet, thereby leading to a reduction in pumping efficiency and longevity of
the pump.
- For future similar project, the student should be made to design discharge pipe
of various sizes and tested to arrive at optimum size and also to determine the
effect of the suction and discharge pipes on flow rates.

48

REFERENCE
Peter, F. (1997). Water pumping device. Southampton London: Intermediate technology
publication.
Osore, O.A. (2013). Fluid Mechanics Lecture Note. Department Of Mechanical Engineering.
The Federal Polytechnic Ilaro (Unpublished).
Classification of pumps.(n.d). In Wikipedia. Retrieved from :
http://www.en.wikipedia.org/w/index.hp?oldid=121515362
Report on Reciprocating pumps (n. d) Retrieved from : www.scribd.com
Ajibola. W.A. (2014). Engineering Materials And Application Lecture Note. Department of
Mechanical Engineering. The Federal Polytechnic Ilaro. (Unpublished).
Okuni, P (2005). Pumping. Retrieved December 20, 2014 from http://
www.google.com/pumping+ retrieve+and+ GUI+by=Patrick+Okuni&Client.

49