PVC Water Pumps

By: Joseph Longenecker September 2010

P V C WAT E R PUMPS

Whats Inside:
Pump Design Manufacturing Process Pump Performance Appendix
I NTRODUCTION The purpose of this document is to show several water pump designs constructed from PVC pipe, explain how to manufacture them, and discuss pump performance and how to improve on these designs.

Copyright ECHO 2007. All rights reserved. This document may be reproduced for training purposes if distributed free of charge or at cost and credit is given to ECHO. For all other uses, contact echo@echonet.org for written permission.

PVC Water Pumps

TableofContents
_____________________________________________________________________________ PumpPerformance PumpDesigns 17 2 RowerPump Definitionofterms 6 HandPressurePump 17 SomePrinciplesofwaterpumping 6 HandSuctionPump 18 RowerPumpPerformance 7 MarblePump 20 PerformanceofMarbleandInertiapumps 8 SockPump 20 Factorsthataffectpumpperformance 8 InertiaPump 21 DesigningaPump:Tradeoffs 8 ReciprocatingRopePump 22 Alternativedesignsforcomponents 9 TreadleSuctionPump 23 Testingmethodologyanddata ManufacturingProcesses Appendix 10 SoftenPVCbyheating 25 Imperialtometricconversions 11 FlarePVCpipe 25 Acknowledgments 11 MakePVCsheet 25 Bibliography 12 CompressPVCpipe 25 Contactformoreinformation 12 CutPVCdiscs 13 DrillPVCwithahanddrill 13 Tapthreadedholes 14 Markaradialvalveholepattern 14 Findtheexactcenterofacircle 15 Deburraholeorpipe 15 Punchaholeinrubbersheet 15 Cutadiscfromrubbersheet 16 CutPVCpipesquare 16 GluePVCpipe 16 GlueaPVCdisctotheendofapipe 16 GlueaPVCdiscinsidetheendofapipe 16 Makealargehoseclamp 16 HeatformaholeinPVC 16 BendPVCpipe

PVC Water Pumps

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Thepumpcylinderisthebodyofthepumpinwhichthe pistonslidesupanddown.Deburrbothendsofthe pipeandglueaTeeontothetopend.Notethat AmericanPVCismeasuredbytheinnerdiameter,while WestAfricanPVCwhichismeasuredbyouterdiameter. Sch.40ismediumwallpipe. InletPipe Theinletpipeextendsfromthefootofthecylinderinto thewater.Thetopoftheinletmustbeequaltothe pumpcylinderdiameter,butitcanbereducedtoa smallerdiameterpipetosavecostandreducepriming time.Asaruleofthumb,theinletpipediametershould giveaflowareathatofthepumpcylinder.This requiresaninletpipediameter0.707ofthecylinder. Dontuseaninletpipelessthanthecylinderdiameter; wastedenergyduetopipefrictionwillbecome significant.However,ifyoubuildasurgechamber, smallerinletpipecanbeused(seethetestingsection). Theinletpipewillneedtobebentdependingonthe watersourceandthemountingangleofthepump.See themanufacturingsectiononbendingpipe.Ifasharp bendisneeded,usea45or90degreefitting. FootValve Thefootvalveisacheckvalve(onewayvalve)that allowswaterintothebottom(foot)ofthecylinderbut notbackout.Arubberwasherisboltedtothecenterof aPVCdiscwitharadialarrayofholes.ThePVCdiscis gluedtothetopoftheinletpipeandthecylinderis heatedandflaredovertheinletpipe.Therubberflaps upwhenthepistonsuckswaterintothecylinder,but bridgesovertheholeswhenthewaterreverses direction. Tightentheboltuntiltherubberjuststartstoliftatthe edges.Iftherubberiscompressedtoomuchinthe center,theedgeswillliftupinaconeshape.Thiswill notpreventthevalvefromclosingduringoperation,but canmakeitbounceopenandloseprime.

PumpDesigns

RowerPump
Therowerpumpisoperatedusingthearmandback musclessimilartorowingaboat.Thecylinderis mountedhorizontallyandthehandleisattacheddirectly tothepistonrod.Itcanbepositionedeitherforstanding orseatedoperation.Theergonomicposition,combined withthe3footstroke,givestherowerpumpan outputof1020gallonsperminute,muchhigherthan otherhandpumps.Liftisupto27feetsuctionandat least8feetpressurewiththeuseofarodseal.

Rowerpumpinstalledataborehole

Components
Dimensionsofallcomponentswilldependonsizesof availablePVCpipe.Listedvaluesareforprototypes builtatECHO.Criticalrelationshipsbetween dimensionsarediscussed,allowingthedesignertobuild apumpsuccessfullyfromanysizepipehedesires.

Rowerpumpcomponents PumpCylinder Material:2Sch.40PVCpipe Length:43

Explodedviewoffootvalvecomponents

PVC Water Pumps

Assembledfootvalve RubberValveFlap Material:Truckinnertuberubber(orotherrubbersheet 1/16thick) Useacircularpunchtomakethecenterhole;thiswill keeptheflapcenteredandreducethechanceofit pullingoffthebolt.Therubbershouldoverlapthevalve holesbyatleast1/16topreventitfrombeingsucked intotheholeattheedge,breakingtheseal.Itshouldbe atleast1/16fromtheedgeofthePVCvalvediscto preventitfromcatchingoninsideofthepumpcylinder whereitflaresoutoverthefootvalve.Bicycletube rubberisnotstiffenoughtobridgethevalveholes, althoughlayeringseveralpiecesmaywork.

Footvalvediscdimensions HoseClamp Thefootvalveisheldinplacewithahoseclamponthe footofthecylinder.Makeeightcuts1/2deepintothe endofthecylindersotheplasticcanflexintogripthe inletpipe.Beforeputtingonthehoseclamp,wrapthe jointtightlywithastripofbicycleinnertube.This providesadditionalsealagainstthesmallamountofair thatwillbeabletoleakbetweentheinletpipeand cylinderfoot.

Thefootvalvejoint,wrappedinrubberandhoseclamped SurgeChamber Material:4PVCpipeandreducers Length:18 Thesurgechamber(optional)isbelowthefootvalve.It absorbssharpvacuumspikescreatedbythepistonand evensouttheflowofwateruptheinletpipe(seethe sectiononpumpperformance).Thesurgechamber shouldhaveavolume2xthepumpcylinder.The diameterandlengtharenotimportantifthisvolumeis maintained.

Rubbervalveflapdimensions PVCValveDisc Material:4Sch.40PVCpipe,flattened(aboutthick) Togettheedgeexactlyflushwiththeinletpipe,cutthe discslightlylarger,glueittotheinletpipe,andfileit downtothepipe.Whentappingthecenterhole,only runthetappartwaythroughsothattheboltstartseasily buttightensup.Makesurethevalveholesareatfar enoughfromtheedgesothattheinletpipeunderneath doesnotblockthem.Seethesectiononalternative checkvalvedesignsfortipsongettingthemostflow areaforyourpipesizewithoutweakeningthevalve.

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preventtherubberfrombindinginthegapasitflexes upanddown. Rodbushing Material:PVCorHDPEplastic Thepurposeofthebushingistokeeptherodcentered soitdoesnotdeformtherubberandallowleaks.HDPE (#2)plasticwearsmuchbetterthanPVCandhashigh lubricity.Someplasticbarrelsaremadefromit.Itcan beflattenedbyheatthesameasPVC.Woodisanother option:Awoodbushingcanreplaceboththebushing discandtheretainerring.Therodshouldslidethrough thebushingwithaslittleclearanceaspossiblewithout sticking.Ifyoulackprecisecuttingtools,seeHeat formaholeinthemanufacturingsection. RetainerRing Thisisasmallsectionof2pipeinsertedabovethehead sealcomponentstoholdtheminplaceandgivethehose clampsomethingtogrip.Sizeittoleaveasmallamount protrudingfromTeefittingtoallowatooltogripit shoulditbecomestuck. HoseClamp Makeeightcuts1/2deepintothetopoftheTeesothe plasticcanflexintogriptheretainerring. Piston Thepistonslidesupanddowninthecylindercreating suctiontopullwaterintothepump.Inthispiston design,therubberdiscsservebothasthepistonsealand asthecheckvalveflap.Onthedownstroketherubber foldsoutofthewayasthepistonmovesthroughthe watercolumn.Ontheupstroke,therubberissucked downagainstthePVCdiscandwaterpressureforcesit outagainstthecylinderwall,sealing.Thisdesign pumpssandverywellbecauseoneverystroketheseal breakscontactwiththecylinder,allowingany accumulatedsandparticlestobeflushedout.

Surgechamberonrowerpump HeadSeal Theheadseal(rodseal)sealsaroundthepistonrodso thatwatercanbepumpedtohigherelevation.Arubber washerissandwichedbetweentwoPVCdiscs,witha PVCbushingontoptokeeptherodcentered.These componentsmustbeassembledonthepistonrodbefore attachingthehandle.Theyshouldfitsnuglybutnot tightlyintotheTeesotheyareeasytoremovefor maintenance.

Explodedviewofheadsealcomponents Rubberwasher Material:truckinnertubeatleast1/16thick Thecenteriscutusingacircularpunch.Itisvery importantthatthecutissmooth,assmallcutsandtears willpropagateunderthecyclicloading.Thediameter shouldbe1/16smallerthantheroddiametertogivea goodsealwithoutexcessivefrictionandstressonthe rubber.Doubleuprubberwashersiftheyarenotthick enough. Rubbersupportdiscs[2] Material:4PVCpipe,flattened(about1/4thick) Thediscthicknessisrequiredsothatastherubberflexes upanddownwiththerod,itisnotcaughtintherod bushingaboveit.Theholediametershouldbeatleast fourrubberthicknesslargerthantheroddiameterto

Explodedviewofpistoncomponents PistonValveDisc Material:4PVCpipe,flattened(aboutthick)

PVC Water Pumps

Thediameterofthediscshouldbe1/8lessthanthe cylinderdiameter,giving1/16clearancewiththe cylinderonallsides.Itisimportantthatthediscbe exactlycircularandthattheholebeexactlyinthecenter. Waterleakageandfrictionwillincreaseastheprecision ofthevalvediscdecreases.Whentappingthecenter hole,onlyrunthetappartwaythroughsothatthebolt startseasilybuttightensup.

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ThewoodplugisinsertedintotheendofthePVCpiston rodbyheatingit.Theplugistaperedwiththelargeend insertedfirsttolockitinplace.Thesmallendisslightly largerthanthepipediameter.Iftheendoftherodis greaterthandiameter,bevelitsothepistonvalve holesarenotblocked.Inthecenteroftheplug,a1/4 holeisdrilledthroughandtapped5/1618toreceivethe pistonbolt.Tapasdeepasthetapwillgo. PistonRodandTHandle Material:PVCpipeandTee Length:Rodis44,eachsideofhandleis5 Gluebothsidesofthehandle,butattachtherodwith twoscrewsthroughthesideoftheTee.Therodmustbe detachedtoreplacetheheadsealrubber.PVCpipeis chosenbecauseitissmoothandwillwearslowlyonthe headseal.Anaddedbenefitisthatthehighflexibilityof thinpipeallowssidetosidemovementofthehandle withoutputtingstressontheheadseal.Ifthepumpis abused,thehandlewillbreakfirst,ratherthanbreaking theheadsealorcylinder.Thepistonrodismosteasily replaced.Seetheappendixforadditionalhandleand pistonrodoptions.

Pistonvalvediscdimensions RubberValveFlap[23] Material:Truckinnertuberubber(orotherrubbersheet 1/16thick) Thediametershouldbe1/16greaterthanthecylinder diameter.Thisallowstherubbertofollowirregularities inthecylinderwallwithoutbreakingcontactor bunchingupattheedges.Itisimportantthattheflapbe exactlycircularandthattheholebeexactlyinthecenter. Waterleakageandfrictionwillincreaseastheprecision ofthevalveflapdecreases.Useacircularpunchto makethecenterhole;thiswillkeeptheflapcentered andreducethechanceofitpullingoffthebolt.Dont usebicycletuberubber;itwillstretchatthecenterhole andtheflapswillbepulledoffcenterandbindbetween thePVCdiscandcylinderwall. Thenumberofrubberdiscswilldependonthethickness oftherubberandthegapsizebetweenthevalvedisc andcylinderwall.Asaruleofthumb,thetotalrubber thicknessshouldbeequaltothegapdistance.Ifthe rubberistoothin,waterwillleakpast;iftoothick, frictionwillbeexcessiveandthepistonmaybindinthe cylinder.Tip:addmorerubberdiscsuntilyoufeelthe rubbergrabbingthecylinderwallwhenyoupullslowly onthepiston,thenuseoneless. PistonBolt Thepistonboltis5/1618x1long.Usegalvanized, stainless,orpaintedhardwaretoresistcorrosion. Woodplug Material:hardwood

Installation
Cylinderangle Thebestangleforthecylinderwilldependonwhether youhavearodseal.Ifyes,setthepumpcloseto horizontal,withthefootvalvethreeinchesbelowthe headseal(thiswillkeepwateronthefootvalvesoit doesnotloseprime).Ahorizontalpullismost ergonomicbothfromastandingandseatedposition.If norodseal,mountthepumpatasteeperangle,30deg fromhorizontal,toreducethedistancewatersplashes outofthetopofthecylinder. Securingthepump Oneoptionistoburrythepumpinamoundofdirt. Anotheristoplanttwosetsofpolesinthegroundatthe headandfootofthecylinder.Insertapegthroughtwo polessothepumpcanrestbetweenthemonit.Lashthe polestogethertosecurethepump.

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Thispumpworksmostefficientlyifsomewaterleaks pastthepistonseal,providingawaterbarriersoair cannotleakpastthesealontheupstroke.Toventthis watersoitdoesnotblowoffthecap,aholeisdrilled inthetopofthecylinderdirectlybelowthecap(onthe darksideofthebelowphotograph).Thecylindercapis onlytosupportthepistonrod.

Rowerpumpclampedbetweentwosetsofpoles SunProtection PVCdegradesinUVlightandbecomesbrittle.Paintthe pump,coveritwithashelter,orburyitinamoundof dirt.

OtherRowerDocumentation
TheMennoniteCentralCommittee(MCC)hasagood constructionmanualfortheirversionoftherower pump.Thisdocumentisavailableinelectronicformby requestfromECHO.

Handpressurepump Thepistonsealissimilartotherowerpump,buttwo rubbersealsareused,oneoneithersideofthePVCdisc. Thiscreatesasealwhenthepistonmovesineither direction.ThepistonrodisPVCpipewithanendcap, tappedtoaccepttheboltthatholdstherubberandPVC discinplace.

HandPressurePump
Thehandpressurepumpisoperatedsimilartoabicycle airpump.Itisintendedtobeplacednearawatersource andforcewateruphilloroveragreatdistance.The pistonissolid,pullingwaterintothecylinderthrough onecheckvalveandexpellingitthroughanother.Check valvesareradialflappervalvesinsertedinbothendsof theTeeatthebottomofthecylinder.Theendsofthe Teeareslottedsimilartotheheadandfootoftherower pump;byremovingthehoseclampsthevalvediscsmay beremoved.Thecylinderis2diameter.The1plastic hoseandballvalvepicturedbelowarefortestingonly; liketherowerpump,itisrecommendedtousesuction anddischargepipingatleasttheareaofthecylinder.

Handpressurepumppiston

PVC Water Pumps

HandSuctionPump
Thehandsuctionpumpissimilarinconstructiontothe rowerpump.Itismoreportableanddoesnotneedto beanchoreddown.Outputisprobablysimilarbuthas notbeenmeasured.Thepumppicturedbelowhasa3 cylinderand2suctionhoseforlargevolumeatlowlift. Itismostcomfortabletooperatethispumpifthelength ofthecylinderrequiresyoutobendslightlyattheknees whenpumping.Thiswillallowyoutopumpwithyour legs. Marblepump Thefootvalveismadebycompressingthe1.25pump cylinderoverapipe,thengluingthesmallerpipein placetomakeaseatfora1glassmarble.Themarbleis heldinplacebyapinthroughthecylinder,permitting themarbletoriseofftheseat.

Marblepumpfootvalve Handsuctionpump TheplungerisPVCpipe.Ashortsectionofpipe isinsertedintotheendbyheating.AringofPVC pipeisinsertedovertheendofthepipe,creatinga grooveinwhicharubberoringsits.Theoringshould beloose,buthavenotravelupanddowninitsgroove. Themarbleseatsontopofthepipeandisheldin placebyapinthroughtherodthatpermitsittoraise ofitsdiameterofftheseat.Inlieuofapin,therodmay beheatedandcrimpedintoanovalshapetokeepthe marbleinplace.

MarblePump
Themarblepumpisnamedfortheglassmarblesused forballcheckvalvesinthepistonandfootvalve.Water isdeliveredthroughthepistonrodonthedownstroke. Aflexiblehoseisattachedtotheendoftherodfor delivery.Thispumpdoesnotneedarodsealtopump uphill.Thesmalldiametermakesitappropriatefor wellsbelowthesuctionlimit.Itworksbestasalift pump(thefootvalveandpistonshouldbesubmerged inthewater).

Marblepumppiston

PVC Water Pumps

SockPump
Thesockpumpisnamedforthesockvalveonthe plunger.Abicycleinnertubeistiedtotheendofthe plungeroverarowofholes.Theplungerpipeis pluggedabovethevalveholes,andendoftheplungeris flaredouttoslidelooselyinthepumpcylinder(a woodenmoldwasturnedonalathetomakethisflare). Thispumpusesthesamefootvalveasthemarblepump (anytypeoffootvalvecanbeused).Onthedown stroke,waterisforcedupthroughtheplungerandout throughtheholes,butistrappedontheupstrokebythe sockvalve.Theflaredplungerformsanimperfectseal, butathighspeedtheleakageisnegligibleandis compensatedforbylackofthemechanicalfrictionofa rubberorleatherseal.Waterdeliveryisthroughthe risingmain,nottheplunger.

ofitwillbepulledbackdownintothecylinder,butif thespeedoftheplungerishigh,thiswillbelowenough thatasignificantamountofwatermaybeliftedupthe risingmain. Thepumpingheadshouldnotchangetheamountof waterthatfallsbackintothecylinderontheupstroke. Objectsthrownupwardundertheinfluenceofgravity willfallatthesamerateindependentoftheirmass. Pumpingheadwillaffecttheforcerequiredtopushthe plungerdown. Thesmallerthegapbetweenplungerandcylinder,the morequicklythispumpwillprime.However,atsome point,frictionwillbecomesignificant.

ReciprocatingRopePump
Thereciprocatingropepumpisadeepwellpumpin whichthepistonisattachedtoamassandraisedand loweredonarope(ithasnopistonrod).Themass providestheforcenecessaryforthedownstroke.Atthe topofthepumpisapulleyorrollersothattheropecan bepulledhorizontallyinarowingmotion.Thepiston andfootvalvecomponentsareotherwisethesameas therowerpump.Mymeasurementsoftherowerpump haveshownaforceofaround14lbsisnecessaryforthe pistondownstroke.Because14lbisalottoaddtothe handleforceofapump,theweightonthepistoncanbe reduced,withtheresultthatitreturnsmoreslowly.In thephotographbelow,thepistonweighs10lbandthis givesatolerablereturn. Thispumpismostappropriatefordeepwellswhere eliminatingthepistonrodcangreatlyreducethecost andmakeextractingthepistonmucheasier.

Sockpumpplunger

InertiaPump
Theinertiapumphasnopistonvalve.Thepistonisa PVCpipewithaplugintheend.Thecylinder/rising mainis1.25pipe.Anytypeoffootvalvecanbeused, butitmustbesubmergedatleast4feetbelowthewater.

Inertiapumpplunger Theplungerisworkedrapidlyupanddown.Onthe downstrokeandplungerdisplacesmostofthewaterin thecylinder;thewatershootsrapidlyupinthesmall gapbetweentheplungerandcylinder.Whenthe plungerreversesdirection,theinertiaofthewaterkeeps itmovingupwardforamoment,creatingapressure dropinthecylinderthatpullsmorewaterthroughthe footvalve.Thewaterwillloseitsmomentumandsome

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Reciprocatingropepump

TreadleSuctionPump
Thisisanopentoptreadlepumpmostsuitedforfilling irrigationcanals.Ithasnospouttodirecttheflowof water.Ithasnobasetositon,butratherapostthatis setintotheground.Withwaterpouringaroundit,the soilquicklysettlesfirmlyaroundthepost.Ifthepump canbesetdowninaditchsothatthebaseofthe cylindersissubmergedinwater,itwilleliminateany suctionairleaks. Treadlesuctionpump ThecylindersarePVCpipe.Thekeytosuccessfully usingthisweakmaterialinatreadlepumpistoisolateit fromanystructuralloads.Waterandpistonsealfriction shouldbetheonlyforcesonthepipe.Inthemodel,the cylindersareclampedtotheverticalframemember. Thetreadlespivotona5/8steelrodwhichkeepsside tosidewobblelow.Cotterpinsratherthannutsare usedonthepivotrods.Theydontfreezeonandare easytomakefromsteelwire. Thebaseofthecylinderisa2Teeandelbowfitting withringsof3pipecompressedoverthemtoexpand thediameter.2pipeisgluedintothefittingsand sawedoffflushtogiveawidesurfaceforthevalveseat. Rubberflappervalvesarescrewedontotheseat(cutthe rubberfromatiresidewall).The3cylindersarethen flaredoverthefootvalves.

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maximumtravelofthepistons;astheropestretches,the pistonswillsitlowerinthecylindersandthestroke lengthwillreduce.

Ropeattachmentdetail

ManufacturingProcesses

SoftenPVCbyHeating
PVCcylinderdetail Pistonsaresimilartotherowerpump,butsizedfor3 pipe. PVCbecomessoftandpliablewhenheatedbetween225 and275degF.Thisbehaviorcanbeexploitedtomake flaredpipeconnectionsandflatPVCsheet,increasing theversatilityofthismaterialinareaswherepipe couplingsandflatsheetaredifficultorexpensiveto obtain.Hotairandhotoilmaybothbeusedtoheat PVC.Oilismoredesirablebecauseitgivessteady uniformheat,butittakeslongertoreachworking temperatureandisdangerousifspilledoraccidentally heatedtoflashpoint.Caution:ifheatedbeyond275 degF,PVCwillscorchandthefumesgivenoffcontain dioxins,neurotoxinsthatbioaccumulateinbodytissue. Hotoilbath Heattheoilslowly.Testthetemperaturewithapieceof PVCwhileheating.Itshouldnotshowanysignsof scorchingwhenheldintheoilforanylengthoftime. Oilhasmuchbetterheattransferpropertiesthanairso thedesiredoiltemperaturewillbeonlyslightlyhigher thanthedesiredPVCtemperature. HotAir Aircanbeheatedbypropanetorch,electricheatgun, fire,etc.Directingthisheatagainstthepipeisbest accomplishedbyputtingaskirtaroundthepipe.Itis importanttokeepeitherthepipeortheheatsource

Pistondetail Theropeisanchoredtothetreadlesbyhookingitover protrudingpinsontheoutsideofthetreadleboard. Thismakesiteasytoadjusttheropelengthtoallowthe

PVC Water Pumps

movingconstantly,astheairtemperaturewillbevery nonuniform.Airtemperaturewillalsobemuchhigher thanthedesiredPVCtemperature.Airhaslowheat transferpropertiesandunlessalargetemperature differenceismaintained,thePVCwillheatveryslowly. Herearesomeexamples: 1. Apropanetorchwithskirtmadefromatincan.The torchheatstheairinthecanatthebottomandthe pipeisinsertedthroughaholenearthetop.The pipeshouldberotatedconstantlyforevenheating. 2. Anelectricheatgunwithatincan.Thepipeis insertedintotheopentopofatincanandanelectric heatgunisaimeddownintothecan.Keeptheheat gunmovingtogiveevenheating. 3. Holdthepipeoverafire.Enoughheatisrisingover alargeareasoaskirtisnotneededtocontainheat aroundthepipe.Ittakespracticetoheatwithout scorching.

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otherpipeandcontractitslightly.Toreducethiseffect, coolthepipeeveryfewsecondsbypullingitoutofthe flaredpipeanddunkinginwaterbriefly.Ifyouneedto makealotofflaredends,itmaybeworthwhiletoturna woodenmoldonalathe.Themoldcanbemadeafew thousandthsofaninchlargerthanthepipediameterto alloweasierinsertionofthepipe.

AflaredPVCjoint

MakePVCsheet
Cutashortsectionofpipelengthwisesoitcanbe unfolded.Heatthepipeuntiluniformlysoftandspread flatandpressbetweentwosmoothandrigidsurfaces. Allowtocooluntilwellsolidified.Usealotofweight whenpressingthesheetflat,otherwiseitwillhave ridgesandripples.SoftPVCdoesnotflowlikepie dough;itremainstoughandrubbery.PVCismadeof chainsofpolymersthatcanslidepasteachotherwhile abovetheglasstransitiontemperaturebutalways remainpartiallyconnectedbycrosslinkmolecules. Whenpressedbetweentwoperfectlyflatsurfaces,the PVCsheetwillstillhaveaslightconvexshapewhen removedduetoresidualstressesinvolvedinunbending thepipe.Tomakeitperfectlyflat,trypressingbetween twoslightlyconcavesurfaces,suchaswidewoodplanks thathavewarpedorcupped.Havingbeenoverbent, thesheetwillspringbackintoamoreflatstate.PVChas amemoryandifyoureheatyourflatsheetagain,itwill curlbackintoapipe.

HeatingPVCwithatorch

HeatingPVCwithanelectricheatgun

FlarePVCpipe
Thisprocessstretchesthepipe,increasingitsdiameter soitwillfitoveranotherpipe.Heattheendofonepipe untiluniformlysoft,theninsertitovertheotherpipe. Allowtocoolenoughtoholdinthehand,thenpullthe twopipesapartwhilebendingthejointbackandforth toloosenit.Onlyflareapipeusingthepipethatitwill bejoinedto:Theheatfromtheflaredpipecansoftenthe

FlatPVCsheet

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a) Ifanadjustableholesaw,loosenthenutand rotatethetwohalvestoslidethecuttingteethin andouttogivethecorrectdiameter(notethat youneedaninnerdiameterbecauseyouwantto keepthecenterofthecutout).Tightenthenut. b) Ifafixeddiameterholesaw,findonethatis+/ 1/8ofthedesireddiameter(rememberto measuretheinsidediameterofthesaw). ClampthePVCsheettoscrapwoodtosupportthe sawasitcutsthroughthebacksideofthesheet. Useeitherahanddrillordrillpresstocutthehole a) Handdrill:Clampthescrapwoodtoasecure object(workbench,vise).Holdthedrillwith bothhandsandtakecaretokeepitsteadyand straight,asthiswillreducethechangeofthe sawcatchingandwrenchingthedrilloutof yourhands.Runatamediumspeedandfeed thesawslowlyintothework.Withdrawthe sawfromtheworkoftenandcleantheteeth withawirebrush,astheplasticmeltstothem andclogsthesaw b) Drillpress:Clampthescrapwoodinthedrill pressviseandadjustthetableheighttobring theworkclosetothesaw.Turnonthedrill pressandadjustthespeedto600rpm.Feedthe sawslowlyintothework 4.Removetheholecenterfromtheholesaw.

CompressPVCpipe
TheprincipleofflaringPVCpipecanalsobeappliedto reducethepipediameter.Putahoseclamparoundthe endofthepipe,heatthepipeuntiluniformlysoft underneaththehoseclamp,insertthesmallerpipeand tightenthehoseclampuntilthelargerpipehas compressedagainstthesmaller.Smallerpipeswillbe lopsidedwhencompressedbecausethehoseclamp screwmechanismputsaflatdentinonesidethat becomesincreasinglynoticeableinsmallerdiameters.

2. 3.

1.25pipecompressedonto3/4pipewithhoseclamp

CutPVCdiscs
Withalathe DrillaholeinthecenterofapieceofPVCsheetandbolt toasteelrodtoclamprodinlathechuck. Note:5/8diametersteelrodistapped5/1618to receiveaboltwhichclampsthediscagainsttheendof therod.Thisprovidesagoodfrictiongriponthedisc andresistsbendingforcesappliedbythecuttingtool. Alternatively,astandardboltorthreadedrodwithtwo nutsmaybeusedtoholdthePVC.

Fixedholesaw(left)andadjustableholesaw(right)

PVCdiscturnedonlathe Withaholesaw 1. Selectholesawsize

HoleSawingusingahanddrill

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Drillpressesholdboththeworkandthebitrigidly andthereislittlebenefitfrompilotholes. Twistdrillbitswillpullthemselvesrapidlythrough asoftplasticlikePVC,particularlywhentheyhavea pilotholetofollow.Thisrapidcuttingofalarge chunkoutoftheplasticcancauseittocrack, especiallyiftheholeisnearanedge.Trytodevelop theskillofpushingthedrilltogetittobite,then pullingbackonittodrilltheholeinaslow controlledmanner. Drillrpmdependsonthesizebit.Smallbitsmust beturnedveryfasttoexpelthechipsfromtheflutes onthebit.Largebitsshouldbeturnedslowly.The speedofthecuttingsurfacesincreasesasthe diameterincreasesandtherpmmustbedecreased inthesameproportiontopreventexcessiveheat buildupthatwilldamagethebit.Thisisvery importantwhendrillingmetal,butwithsofter plasticitisnotanissueandbitscanberunfaster.

HoleSawingusingadrillpress Withasawandfile 1. MarkoutthediscdiameteronthePVCsheetwitha compassorbytracinganobjectofthecorrectsize. 2. Cutoutsideofthislinewithmultiplesawcutsto givetheapproximateshapebutleaveextramaterial forthefiletoremove. 3. Filetheremainingpointsdowntotheline.Make suretoholdthefileperpendiculartothediscsothe edgeisnottapered.

Tapthreadedholes
Atapisusedtocutinternalthreadsinthehole.Tapping apartofteneliminatestheneedforanutonthebolt. 1. Drillaholesmallerthanthethreadsize, approximatelyequaltothediameteratthebaseof thethreads.Tapdrillchartswillgivetheexactsize. 2. Twistthetapdownintothehole;pushtogetit startedbutafterthatitwillpullitselfin.

Straightcutsaroundperimeterofdisc,edgefiledround

DrillPVCwithahanddrill
PVCissoft,andalargebitwillwanderaroundalot beforeitgetsindeepenoughtokeepitselfcentered. Tomakeastraightroundholeinthecorrect location,drillasmallpilothole(1/8)first.Thiswill doalottokeepthebitcentered.Forevenmore accurateholes,stepupthediameterbyincrements of1/8untilyoureachthedesireddiameter.Note: TappingthreadsinaPVCdisc. Iftappingmetal Lubricatethetapheavilywithcuttingoil.Turnthetap1 turnforward,1/4turnbackwardtobreakthechipthatis formedasmetalisshavedofftheinsideofthehole.This willpreventthetapcuttingteethfromgettingclogged

PVC Water Pumps

andbinding.Veryeasytotwistatapinhalfifyoudont followthisprocedureinmetal.Notanissuewithsofter plasticandwood. Ifthereisnotap... Whenthreadingaboltintoplasticorwood,itisnot necessarytotapthehole,themetalboltwillcutitsown threads,althoughitwillgoinwithmuchmore resistance.Ifyouhaveaveryhardwoodorplastic, tappingisprobablynecessarytokeepfromsplittingthe wood.Ifthereistoomuchresistance,theholecanbe drilledoutlarger,butkeepinmindthatlessthreadwill beincontactwiththewoodandthereforelessholding power. Acrudetapcanbemadefromasteelbolt.Cutaslitin theendofthebolt;thecutedgesofthreadwillbesharp cuttingsurfaces.Aluminumcanbetappedwiththis method.

15

Markingholecenterswithacompass Freehand Drawdiameterlinesdividingthediscintosixroughly equalsegments.Measurefromthecenteroredgeofthe discandmarktheholecenters. Makeatemplate Cutadiscfromsheetmetalandmarkoutthehole pattern.Punchasmallholetomarkthecenterofeach hole.ThemarksareeasilytransferredtothePVCdisc withacenterpunch.

Asteelboltslitattheend,usedtotapsoftermaterials

Markaradialvalveholepattern
Withacompass Scribeacirclethatwillpassthroughthecentersofthe holes.Keepingthecompassatthesameradius,place thepointontheedgeofthecircleandsteparoundthe circlemakingmarksateachstep.Thiswilldividethe circleintosixequalsegmentsandmarkthecentersof theholes.

Holepatterntemplate

Findtheexactcenterofacircle
Placethepointofasquareontheedgeofthecircleand markwheretheedgesintersectthecircle.Drawaline connectingthesetwomarks;itwillbeanexactdiameter. Drawtwoorthreediametersandmarkwherethey intersect.

PVC Water Pumps

16

Punchaholeinrubbersheet
Circularpunchesmakeacleancutinasoftmaterialsuch asrubber.PlaceapieceofflatPVCorhardwood underneaththerubbertocutagainst(dontusemetal,it willdullthecuttingedge). Indexcardusedtomarkendpointsofacirclediameter.

Deburraholeorpipe
Withadeburringtool Dragthecuttingedgeclockwisearoundtheinsideedge ofthehole,applyingfirmpressure.Deburringtoolscut inonlyonedirection,mostlikelyclockwise.

Fromlefttoright:standardcircularpunch,metalpipe sharpenedtoacuttingedge,valvestemsharpenedtoacutting edge,drilledoutmetalstocksharpenedtoacuttingedge.

Cutadiscfromrubbersheet
Option1:PVCtemplate 1. Tracethetemplate(centerholeandouterdiameter) ontorubbersheetandcutoutsideoflinetoleave 1/8extramaterial 2. punchthecenterhole 3. bolttherubbertothetemplateandcutaroundit withscissors.Makestraightcuts,keepingthe scissorsbladevertical.Donottrytofollowthe curveofthetemplate,asthiswillstretchtherubber andthecutwillnotfollowthetemplate.

Deburringtoolremovingburrsoninsideedgeofpipe Withafile Toavoidmakinggroovesincurvedsurfaces,movethe filesidewaysaroundtheinsideofthepipe(drawfile). Filescutonlyinonedirection,usuallyawayfromyou. Dontcutbackwards,itdullstheteethandplugsthem withfilings.

Filingtheinsideedgeofapipe Rubberdiscbeingcutontemplate

PVC Water Pumps

Option2:freehand 1. Tracearoundanobjectofcorrectsize.Or,tracean objectclosetothecorrectsizeandmeasurefromthis lineandmakeseveralmarksaroundthe circumferencetoguideyou. 2. Cutoutthediscwithscissors. 3. Findthecenterandpunchthehole.

17

GlueaPVCdiscinsidetheendofapipe
Cutthedisctofitexactlyintothepipewithnolarge gaps Ifyouarenotsuccessfulatgettingagoodfit,heat thepipeandcompressitaroundthedisc.Mark theirpositionrelativetoeachother. Useplentyofgluesothatgapsarefilled.

CutPVCpipesquare
Constructamiterboxfromwood.Thisisachannelthat willcradlethepipesecurelywhileyoucut.Ithasaslot (cutwithyoursaw)perpendicularacrossittoguidethe sawblade.Onevariationonthestandardmiterboxisto hingeoneflangeofthechannel,makingthebox adjustableforseveralsizesofpipe.

Makealargehoseclamp

GluePVCpipe
1. 2. Deburrtheedgesofthepipeandfittingsotheydo notscrapeoffthegluewhenthepipeisinserted. ApplyPVCprimertobothsurfacestocleanand softenthepipesurface.Allowprimertodry, leavingatackysurface.Donotgetprimeronparts ofthepipethatwillnotbegluedtogether,ithas beenfoundtoweakenthepipeleadingtofailure. ApplyPVCcementtobothsurfaces.Insertthepipe intothefittingwhilerotating1/4turntoevenly distributetheglue.Holdfor30secondsuntilsetup. Thejointwillcureoverafewhourstoreach maximumstrength. Twohoseclampslinkedendtoend

HeatformaholeinPVC
Ifyouneedaholeofexactsizeforarodbushing,butdo nothavethenecessarytools,trythis: 1. Drillaholethenextsizesmallerthanthedesired hole 2. Heattheedgeoftheholetosoftenit. 3. Inserttherodtospreadtheplastic.IftherodisPVC pipe,keepitmovinginandouttoavoidsoftening therod. ThisworkswithPVCandHDPE(#2plastic).Ifthehole hastobespreadsignificantly,itwillprobablybe difficulttogettherodstarted.Trybevelingtheendof therodormakingataperedmoldfromwood.

3.

GlueaPVCdisctotheendofapipe
Makesuretheendofthepipeissquareandflatand thediscisflat.Toresolveslightproblemswith eithersurface,heatthediscandpressthepipedown ontoituntilitsolidifiesagain.Marktheirposition relativetoeachother. Whengluing,applyfirmpressuretoholdthedisc againstthepipeandholditforafewminutesat least.Unlikeapipejoint,thereisnoforcetokeep thepiecesfromspringingapartwhilethegluesets. Letcureforseveralhoursbeforedoinganything withthisassembly.

BendPVCpipe
Fillthepipewithsandandcapbothends.Heatthe sectiontobebentandformitaroundabucketorlarge pipe.

PVC Water Pumps

18
differenceandflowrate.Ifnotenoughpoweris available,apistonpumpwillstallandacentrifugal pumpwillspinbutnotdeliveranywater. Asuctionpumplowersthepressurebelow atmosphericairpressuresothattheatmospherepushes waterintothepump.Forthisreason,suctionpumpsare limitedintheorytoamaximumdepthof34feet.In practicethismaximumsuctiondepthisreducedto around27feetduetolossesfromfluidfrictionandfrom acceleratingthewateroneachpumpingstroke.A pressurepumpraisesthepressureaboveatmospheric sothatwaterispushedoutofthepump;theheightis onlylimitedtotheenergysuppliedbytheoperator. Somepumpsarecapableofbothsuctionandpressure pumping. Reciprocatingpistonpumpsrequiretwocheckvalves;as thepistonmovesupanddowninthecylinder,wateris suckedintothecylinderthroughonevalveandexpelled throughtheother. Sourcesofwastedenergyinpumpsare: Fluidfrictionaswaterincreasesspeedtoflow thoughsmallorificesincheckvalves. Mechanicalfrictionofsealsagainstmovingcylinder wallsandpistonrods. Forceneededtoopen(crack)checkvalves. Pipefrictioninthesuctionordeliverypipe. Pipefrictionisoftenthemostsignificantbecausepipeof toosmalldiameterisusedbecauseitischeaper.Flow frictionincheckvalvesandslidingfrictioninsealscan behighinapoorlydesignedpump. Asuctionpumpcannotallowairtoleakpastitspiston oritwillfunctionverypoorly.Itismoredifficultto makeasealairtightthanwatertightbecauseairisless viscous(itflowsmoreeasily).Ifthesealhassmallgaps, negligibleamountsofwaterwillleakthrough,but significantamountsofair.Thisissueiseasilysolvedby havingwateronbothsidesofthepistonseal.Inmany suctionpumpdesigns,oneofthecheckvalvesispartof thepiston.Onthedownstroke,thepistonmoves throughthecolumnofwaterinthecylinder.Onthe upstroke,thepistonsimultaneouslyexpelswaterfrom thecylindertopandpullsmorewaterintothebottom throughthefootvalve. Theneedtocreatesuctioncanbeeliminatedbyplacing thepumpcylinderbelowwater.Mostwellpumpsare

PumpPerformance

Definitionofterms
PressurePump:apumpthatmoveswaterby raisingitspressureaboveatmospheric SuctionPump:apumpthatmoveswaterby loweringitspressure.Atmosphericpressureforces waterintothepump. LiftPump:apressurepumpsubmergedinawell Head:verticaldistancetowhichwaterisbeing raised. PressureLoss(HeadLoss):adropinpressurewhen waterpassesthrougharestrictionorlengthofpipe. Thisislostenergy. RisingMain:Inaliftpump,thepipeconnectingthe pumpcylinderwiththepumphead SuctionPipe:Inasuctionpump,thepipefromthe pumpcylinderdowntothewater. PumpHead:Theabovegroundmechanismfor operatingaliftpump SweptVolume:thevolumesweptbythepistonin thecylinderduringtheextentofitsmotion.This maybegreaterthanvolumeofwateroutputif pistonleakageissignificant;itmaybelessthan volumeoutputifinertiaofwaterkeepsitmoving significantlyafterthepistonreverses. DirectActionPump:Thepumphandleisdirectly attachedtothepistonrod(nopivotinghandleto generatedleverage).

SomePrinciplesofWaterPumping Pumpsmovewaterbycreatingapressuredifference thatisgreatenoughtoovercomegravityandfluid resistance.Inapistonpumpthisisdonebypositive displacement:Thewaterisforcedtomovebyaclose fittingpistoninacylinder.Theflowrateisconstant withthedisplacementofthepistonandthepressure varieswiththeresistanceofthepipeline.Ina centrifugalpumpthewaterisspunwithanimpellerto raiseitspressurebycentrifugalforceagainstthe impellerhousing.Thepressureisconstantwiththe rotationspeedoftheimpellerandtheflowratevaries withtheresistanceofthepipeline.Thepowerrequired tooperateapumpisproportionaltothepressure

PVC Water Pumps

ofthistypeandarereferredtoasliftpumps.Mostso calledpressuretreadlepumpshavepistonswhichonly seewaterononeside.Thesearecapableofsuctionand areadvertisedassuch,butwillworkmosteffectively whenthepressureheadismuchgreaterthanthesuction head.Watermustleakpastthesealsothateachpiston haswatersittingontopofitanddoesnotsuckair. Allofthepumpsdescribedinthisdocumentare intendedtobeusedasdirectactionpumps,i.e.the handleisdirectlyattachedtothepumprod.No leverageisprovided.Thediameterofthepumpis determinedbasedonthewaterdepth.Thismakesthe mostsensewhenyouarebuildingthepumpyourself andhaveawiderangeofdesignoptions.Nothingis gainedbyusingalargercylinderandthenshortening thestrokebyuseofalevertogainmechanical advantage.Asmallercylinderwithalongerstrokecan givethesamevolumeatlowercost.
2. Flow Rate from a 2" Rower Pump as a function of Work Input for Three Suction Pipe Options 20 18 16 Flow Rate (gpm) 14 12 10 8 6 4 2 0 0.06 0.08 0.10 0.12 Work Input (hp) 0.14 0.16 0.18

19

0.20

1" pipe with surge chamber 1" pipe 1.25" pipe

RowerPumpPerformance
Thefollowingtests(graphs14)usedatwoinchrower pumpinaborehole.Thesuctionpipewas27feetlong andthewaterlevelwas7feetbelowthepump.
1. Flow Rate from a 2" Rower Pump as a function of Handle Force for Three Suction Pipe Options
20 18 16 Flow Rate (gpm) 14 12 10 8 6 4 2 0 20 25 30 35 40 45 50 Handle Force (lb)

Theseflowratesseemgooduntilyouconsiderthatyou areonlyliftingthewater7feet.Theforcerequiredto holdupacolumnofwatercanbecalculatedasF= ghA. F=Force(lb) =density1(slug/ft3=lbs2/ft4) g=accelerationofgravity(ft/s2) A=cylindercrosssectionalarea(ft2) Forwater,g=62.4lb/ft3 62.4lb 7 ft 3.14in 2 ft 2 ft 3 9.5lb 12 2 in 2 Itshouldonlytake9.5lbofforcetoliftthiswater.This isknownasthestatichead,theweightofthewater columnatrest.Therestofthehandleforce(dynamic head)islostasfrictionmovingthewaterthroughthe suctionpipeandfootvalveandasforceneededto acceleratethewateroneachstroke.

1" pipe with surge chamber 1" pipe 1.25" pipe

Density is defined as mass per unit volume. A slug is a unit of mass, analogous to the kilogram.

PVC Water Pumps

3. Force lost to Friction in 2" Rower Pump as a fuction of Flow Rate for Three Suction Pipe Options 45 40 Handle Force Lost (lb) 35 30 25 20 15 10 5 0 8 10 12 14 16 18 20
20 18

20
fasttogivethesamevolume,thereforedynamiclosses willbemuchlesssignificant. Forlonghorizontalruns,pipefrictionlossesbecome moresignificantthanvalvelosses.Thefollowingtests (graph5)useda2rowerpumpinaboreholewith varyinglengthsofhorizontalpipe.Thesuctionpipe diameterwas1.25.Theverticalsuctionpipewas9feet longandthewaterlevelat7feetbelowthepump.
5. Flow Rate in a 2" Rower Pump as a function of Horizontal Run

Flow Rate (gpm)

1" pipe with surge chamber 1" pipe 1.25" pipe

Flow Rate (gpm)

4. Work Lost to Friction in 2" Rower Pump as a fuction of Flow Rate for Three Suction Pipe Options 0.18 0.16 0.14 0.12 0.10

16 14 12 50 lb 10 8 6 4 2 0 40 30

Work Lost (hp)

0.08 0.06 0.04 8 10 12 Flow Rate (gpm) 14 16 18 1" pipe with surge chamber 1" pipe 1.25" pipe 20

20 Horizontal Run (ft)

40

60

Theseresultslookdepressing,butconsiderthatapump thissizeisnotmeantforthehighflowratesseeninthis test.Thetwoinchpumpisbettermatchedtodeeper wellswhereitwillhavemorestaticheadandtheuser willnotbeabletopumpasfast,reducingthedynamic head. Supposeawellis27feetdeep,apersoniscapableofa50 lbpull,andhispumphasasurgechamber:37lbof handleforceisneededtoliftthewater(statichead), leavingonly13lbtowasteasfriction(dynamichead). Fromchart3,hecanpumpabout12gpm. Forshallowerwells,usealargerdiameterpump.The rowerpumpcaneasilybemadefrom3or4pipewith correspondingchangesinthevalvedimensions.A3 pumpcanprobablybeusedupto15feetdeep(static headatthisliftrequires46lbhandleforce),anda4 pumpusedupto8feetdeep(43lbhandleforce).The largerdiameterpumpswillnotneedtobestrokedas

Fromthischartweseethattheamountofwateraperson canpumpdecreasesabout3.5gallonsovera60footrun. Asurgechamberandlargediameterpipearegood investmentsforlongerruns. Canwedecreasedynamiclossessignificantlybyusinga lessrestrictivevalve?Thefollowingchartcompares pumpswithdifferentfootvalves.Oneisaradialpattern ofsix7/16holes,theotherisasideflappervalveovera single1.5diameterhole.Theflappervalveallowsa persontopumpfourmoregallonsperminutethandoes theradialvalve.However,itmaystillbeinferiorforthe applicationbecauseitismoreeasilydamaged.
Comparison of Radial and Flapper Check Valves 25

20 Flow Rate (gpm) Radial Valve Flapper Valve

15

10

0 25 30 35 40 45 Handle Force (lb) 50 55

PVC Water Pumps

Otherobservations: IbuiltarowerpumpfromclearPVCpipeandobserved thatifthepumpisstrokedfastenough,themomentum ofthewaterwillkeepitmovingcontinuallyupward, evenduringthedownstrokeofthepiston.Thefoot valvewillneverclosecompletely.Thiseliminatesthe problemofwaterleakingbackthroughthevalvewhileit isclosing,andtheproblemofthevalveslammingshut anddamagingtheseatortheflap. Theorizingabouttheaboveresults,thesurgechamber requireslessforceatthehandle,butvolumetric efficiencyislowerbecauseasmallermassofwateris accelerated.Morestrokesareneededtomovethesame amountofwater,sothenetpowerrequiredissimilarto thelargerpipe.The1.25piperequiredconsiderably moreforceforagivenflowrate,butthisforcetakesthe waterfurtherbecauseitsmomentumcontinuestomove itupthepipeevenafterthepistonhasreversed direction

21

FactorsthatAffectPumpPerformance
Fluidresistanceandcavitationincheckvalves. Checkvalvesgivealotofresistancetofluidflow.This translatestomoreforcerequiredatthehandletomove thewater.Furthermore,aswaterspeedsuptogo throughthevalveorifices,itspressuredrops,eventually reachingthevaporpressure.Atthispointitflashesto vapor(waterboilsatambienttemperatureifthe pressureislowenough).Whenthevaporbubbles collapse,theysendshockwavesthroughthewater column.Theshockwavecanburstapipe,especiallyata Torelbow.Or,ifthevaporbubblescollapseona surfaceinsidethepump,theysendshockwavesthrough thatmaterialandeventuallycausepittinganderosionof thesurface.Thisprocess,calledcavitation,isaleading causeofdamagetopumpsandvalves.Cavitationis moreanissueinthefootvalveofasuctionpumpthan thepistonvalvebecausethewaterpressureisalready lowerduetothesuctionrequiredtoliftthewater.If cavitationisoccurringinahandpump,onesolutionis topumpslower,reducingthevelocityofwaterthrough thecheckvalveandthusreducingthepressuredrop. Anothersolutionistomakethevalveorificeslarger, achievingthesameresult. Lengthofpiping Thelongerthepipe,eithersuctionordischarge,the greatertheforcesrequiredtoacceleratethewateron eachstroke.Thediameterofthepipedoesnotaffectthe accelerationforce3. Pipediameter Thesmallerthepipediameter,thefasterwatermust flowforthesameoutput.Frictioninpipesincreases withthesquareofvelocity4.Pipecrosssectionalarea increaseswiththesquareofthediameter.So,halving thediametergives1/4thecrosssectionalarea,which givesfourtimesthevelocity,whichgives16timesthe flowfriction.Asaruleofthumb,Isuggestthatthe suctionpipediameterbenolessthanhalfthediameter
3Inasmallerdiameterpipe,lesswatermassisbeing accelerated,butitbeingacceleratedtoahighervelocity.These twoeffectscancelout. 4 Therelationshipbetweenflowvelocityandfluidfrictionis complicatedforturbulentflow;Itisonlyaroughguesstosay thatdoublingtheflowwillresultinfourtimesthefriction.

Marble&Inertiapumps2Performance
Thesewereverycrudetests,measuringhowfastthe pumpcouldfilla5galbucket.Theliftwasabout6feet andthepumpcylinderextended12feetintothewell. Theinertiapumpcouldoutputaround4gallonsper minuteandthemarblepumpcouldoutput57gpm. However,themarblepumpwasmuchmoretiringto operateandrequiredtwohandsatthehighendofits flowrange. Pleasenote:Theseperformancevaluesreflectasingle operatorandasinglewaterdepth.Theinertiaand marblepumpsreactverydifferentlywhenthepumping speedischanged,asitwouldifthewaterweredeeper andrequiredmoreworktolift.Theinertiapump greatlydecreasesinefficiencywhenitisstrokedslower. Themarblepumpincreasesinefficiencyatslowerspeed becausethereislessresistanceinthepistoncheckvalve. Iftheinertiapumpwillbeusedatlargelifts,itshould haveaverysmallgapbetweentherisingmainandthe plungersothatthewatervelocityandresistanceto reversingdirectionarehigh.
Therubbersockrippedoffofthesockpumpsometime duringthetestsoitsresultswereinconclusive.
2

PVC Water Pumps

ofthepumpcylinder.Ideallyitwillbenolessthanhalf thearea,whichrequiresadiameter0.707ofthepump cylinder.Fora2pumpcylinder,use11/4or11/2 suctionpipe.Ifthepipeisrunningalonghorizontal distance,itmaybedesirabletoincreaseitevenmore. Surgechamber Asurgechambersmoothesoutapulsatingflowina pipeline.Inthecaseofarowerpump,thesurge chamberispositioneddirectlybelowthefootvalve.On theupstroke,thepistonsuckshalfofitswateroutofthe surgechamber,withtheotherhalfcominguptheinlet pipe.Thiscreatesavacuuminthesurgechamberthat pullswaterbackintoitduringthedownstrokeofthe piston.Thus,theintermittentflowofwaterinthe cylinderistransmittedintoamoreorlessconstantflow ofwaterintheinletpipe.Watervelocityishalfasgreat andthereforepipefrictionis1/4thasgreat. Surgechamberscanalsobeusedonthepressuresideof apump.Theybecomemoreandmorenecessarythe longerthepipelineisandthemorewatermustbe acceleratedoneachstroke.Withsinglepistonpumps, theyallowuseofsignificantlysmallerdiameterpiping. Withtreadlepumps,duetotheirtwocylinders deliveringwatercontinually,theycannotreducepipe diameterbutstillwillreducepressureshockstothe pumpifconnectedtoalongpipeline. Asaruleofthumb,asurgechambershouldhavea volume2xthecylindervolume.Thelargerthevolume, thesmallerthepressurevariationinthechamberand themoresteadytheflowuptheinletpipe.Theperfect chamberwouldmaintainaconstantpressureregardless oftheirregularityofthepiston.

22
Pistonsealmaterial Aleathercupsealispressedagainstthecylinderwallby thepressureabovethepiston.Thiscreatesaverygood seal,butalsosignificantfrictionifthecylinderwallis notsmooth.PVCcylindersareeasilyscoredand roughenedbygritthatgetstrappedbetweenthecup sealandthecylinderwall. Therubberdiscpistonsealdeflectsintothegaparound thePVCsupportdiscwithincreasingpressure.This allowssmallamountsofwatertoleakpast,increasingas thepressureincreases.Theselossesareinsignificant comparedtothepumpoutput,buteliminatecontact betweentherubberandthecylinder,eliminating mechanicalfriction.Sandinthewaterisnotaproblem becausetherubberdiscsfoldawayfromthecylinderon everydownstroke,flushingoutanysandthatmayhave becometrapped.OnepumpatECHOwasusedtobail waterfromaholeandstillfunctionedevenwithafoot ofsandaccumulatedontopofthepiston.

DesigningaPump:Tradeoffs
Pipecost Suctionanddischargepipewilloftenbeamuchgreater costthanthepump.Smallerdiameterpipeischeaper, butyouwillgetlesswaterbecausemoreenergywillbe losttofluidfriction.Investinlargerpipe!Humanlabor isnotcheap!Weonlyputout1/10ofahorsepower averageoveradaysworkandwewanttomakethe mostofit. Pistonrodmaterial Metalisstrongerandcanbebentbackifdamaged. StainlesssteelandPVCaresmoothandwillnotrust. PVCisweakbuteasytoreplace,andifabuseditwill breakinsteadoftransferringloadstothepumpand breakingotherparts.PVCflexesmore,allowinga persontopullcrookedlyonthehandlewithoutcausing alotoffrictionintherodbushing. Checkvalves Sideflapcheckvalveshavemuchlowerflowresistance, buttheyareeasiertoripoffortobecomeaskewsothe flapdoesnotfullycoverthehole.Theyalsoopen

Surgechamberonarowerpump:4Sch40PVC,18long

PVC Water Pumps

furtherandsowhentheyclosemorewaterslipsback throughandthevalveslamsharder.Sockvalvescanrip offmoreeasilythanflapvalves.Largerholesinradial patterncheckvalvesgivelessresistancebutweakenthe valvedisc. OverallCost Itisageneralrulethatthecheapestpumpswillhave lowerflowratesandusethebodylessergonomically. Moreexpensivepumpsarebuiltstrongenoughtouse strongermusclesandaremorecomplexinordertouse musclesinthemostcomfortableposition.So,themarble pumpisverycheapandeasytobuild,butawkwardto operateandgivesasmallflowrate.Thetreadlepump ontheotherhandismostexpensivebutproducesfar morewaterbyusingthelegmuscles.

23
assembly.Valveflapscanbemadefromtiresidewallor frominnertubewithabackingdisctogiveitrigidity.

Sideflapperfootvalve

AlternativeDesignsforComponents
FootValve Variationsontheradialholearray: Therearemanypossiblepatternsofholesforavalve witharubberflapboltedinthecenterofthevalvedisc. Layoutapatternofholesappropriateforthediameter ofthepump.Consideringthefollowing: Thevalvemustnotcatchonthecylinderwallwhen itopens. Therubbermustoverlaptheholesbyatleast1/16 ortheedgewillbesuckedintotheholeandbreak theseal. Distancebetweenholesshouldbe1/2thehole diametertomaintainstrengthofthedisc.Ifthedisc isthickerthan1/10ofitsdiameter,thismaybe reduced.Usegoodjudgment. Maximizethetotalareaoftheholes Forthesametotalarea,fewerlargerholesgiveless flowresistancethanmore,smallerholes. Holesneartheperimeterwillgivelessresistance thanholesnearthecenterbecausewatercanpush therubberflapfurtheroutoftheway. Sideflappervalve: Thesideflappervalveismadebyflaringand compressingpiecesofpipetobuilduptheendofa1.5 inletpipeuntiltheendisthickenoughtoscrewavalve flapto.The2pumpcylinderisthenflaredoverthis

Piston Leathercupseal: TheleathercupissandwichedbetweentwoPVCdiscs witharadialholepatterncoveredbyarubbervalve flap.Thecenteroftheleatheriscutout,leavingalip about1/8wideforthePVCdiscstogrip.Cuttheinner PVCdisctofittheleathercup,butsoaktheleatherfirst forafewdayssoyouwillknowitstruedimensions. CutthelowerPVCdisctofitlooselyinsidethepump cylinder.TapthePVCdiscstoreducehardware.When assembling,lineuptheholesinbothdiscs.

Leathercuppistonseal RubberdiscsealwithsolidPVC: Therubberdiscpistonsealcanbeusedwithoutdrilling holesinthePVCdisc.MakethePVCdiscsmaller,1.75 diameterfora2cylinder,andtherewillbesufficient waterpassagearoundthedisc.Usemorerubberdiscsto bridgethegap.(ThesquarepieceisanutcutfromPVC sheetandtapped.)

PVC Water Pumps

24

Alternativehoseclamp Rubberdiscpistonseal Handle PVCpistonrod: Shapeawoodhandleandboreaholethroughthe center,slightlysmallerthanthePVCpipe.Heattheend ofthepipeandinsertintothehole.Whencool,drill throughthewoodandinsertascreworpintosecurethe rod.ThiswilllikelybestrongerthanthePVCTee handle.

TestingMethodologyandData
MeasuredQuantities Handleforce(lb):mechanicaldialforcegaugebuilt intopumphandle Volumeoutput(gal):57galplasticbarrel Time(s) Numberofstrokes:countedbypersonpumping Strokelength(ft) CalculatedQuantities Flowrate,gallonsperminute=volume(gal)/time (s)*60(s/min) Workinput,horsepower(hp)=strokelength(ft)* strokecount*handleforce(lb)/time(s)/550(ftlb/s perhp) Dynamicforce:subtractstaticforcefromtotalforce. Equipment 2rowerpumpwithheadsealandradialstylefoot valve borehole28feetdeep,watertableat7feet platformtomountpump supportsforsuctionpipeonhorizontalruntest 55galplasticbarrelwithflappervalvedrainin bottom(holds57galtobrim) outletpipetobarrel handleforcegauge timepiece Procedure ForeachtestItimedhowlongittooktofillthe57gal barrel.Eyeingtheforcegaugeinthehandle,Iwasable tomaintainaconstantaverageforceonthehandle, withinafewpounds.

WoodhandleforPVCpistonrod Metalpistonrod: Drillandtapaholethroughthewoodhandle.

Woodhandleformetalpistonrod HoseClamp Drillaholeinbothendsofametalstrap,bendintoa hoopwithearsstickingout,andputaboltthroughthe holes.Thisprobablyhasatightergripthanahose clampandismoreeasilypaintedforcorrosion protection.

PVC Water Pumps

1suctionpipewithsurgechamber Force(lb) 40 30 20 time(s) 178 211 315 strokecount 178 181 179

25

1suctionpipenosurgechamber Force(lb) 50 40 30 time(s) 259 283 369 strokecount 138 159 169

1.25suctionpipenosurgechamber Rowerpumpwith27suctionpipeinborehole force(lb) time(s) strokecount 50 189 142 40 226 149 30 323 161 Testsofsuctionpipeoptions FlapperValve,1.25suctionpipe force(lb) time(s) strokecount 50 154 128 40 182 130 30 242 132 Testusingpumpwithsideflappervalveinsteadofradialvalve norun HandleForce Timetopump (lb) 57gal(s) 50 196 40 252 30 299 20 480 42 225 55 189 30 297 20run HandleForce (lb) 40 30 45 50 40 30 45 35 Timetopump 56gal(s) 260 374 223 200 257 351 204 296

Rowerpumpwith60horizontalrunfromborehole

Handleforcegauge(060lb) RawData volume 57gal strokelength 2ft lift,vertical 7ft inletpipe,vertical 27ft forcepistonreturn 14lb Fixedquantitiesforalltests

PVC Water Pumps

40run HandleForce (lb) 50 40 30 45 35 Timetopump 56gal(s) 224 309 366 230 301

26
Examples Convert10gallonsperminute(gpm)tolitersperhour (lph) 10 gal 60 min 3.79liters 2,274l min hour gal hr Convert6metersofwaterintopoundspersquareinch (psi) 6m 14.7 psi 8.6 psi

60run HandleForce Timetopump (lb) 56gal(s) 50 282 40 337 30 430 45 301 35 393 Testsofhorizontalrun

10.3m

Acknowledgments
Theideafortherubberdiscpistonsealandcheckvalve originatedwithMattKiehlatMessiahCollegein 2003.IlatersawasimilardesigninWayneNiles PVCpumpdesignedinHaiti. Theideafortherubberdischeadsealoriginatedwith MessiahCollegestudentsworkingontheWestAfrica PumpProjectin2001. Therowerpumpinthisdocumentisinspiredbythe MCCWestAfricaRowerPump,althoughallofthe componentsaredifferent.

Appendix

Imperialtometricconversions
Conversionfactors 1inch=25.4mm 1gallon=3.79Liters 1atmosphere=14.7psi=34feetofwater=10.3metersof water5 1ft^3water=62.4lb 1horsepower=~550footpoundspersecond=746watts Calculations Writeeachconversionfactorasaratio(fraction). Multiplyfactorstogetheruntilyougetthedesired dimensions.Unitscanceloutwhentheyaredividedby themselves:gal/gal=1,justlike4/4=1.

Bibliography
MCCRowerPumpconstructionmanual WayneNilespictorialmanualforconstructinga PVChandpump(ECHOelectronicfiles) WorldVisionAustraliabrochureforconstructing theRusPump(EHCOpaperfiles) TerryWaller,SketchesofaPVChandpump(ECHO paperfiles) DocumentsdescribingtheCanzeePump(online) MessiahCollegeSeniorEngineeringProjectreport, 2001:IntegratedPumpDesign

Pressure is defined as a force per unit area, e.g. pounds per square inch: 1 atmosphere is the pressure at sea level exerted by the weight of the earths atmosphere. Pressure can also be defined in terms of the weight of a column of water: A 6 meter high column of water exerts a force of 8.6 pounds per square inch. The volume of water has no effect on the pressure, i.e. a 2000 gallon tank and a two inch PVC pipe will have the same pressure at the base if they are the same height.

Contact
JosephLongeneckerformoreinformation: jblongen@gmail.com RevisionHistory:Lastmodified25Oct.2010JBL