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A Design Manual For Water Wheels
A Design Manual For Water Wheels
A Design Manual For Water Wheels
by: William
Published by: Volunteers in Technical Assistance 1815 North Lynn St. Suite 200 P.C. Box 12438 Ariington, VA 22209 USA Paper copies are $ 4.95. Available froi?: Volunteers in Technical Assistance 1815 North Lynn St. Suite 200 P-0. Box 12438 Arlington, VA 22209 USA Reproduced by permission Technical Assistance. of Volunteers in
Reproduction of this microfiche document in any form is subject to the same restrictions as those of the original document.
with for
details village
for
applications
William
G. Ovens
c\ VITA,
Inc.
1975
1 1
II III TV
of the Problem - Advantages for and Disadvantages Design Flow Rates Considerations Torque vs. Speed; Required Design Design Considerations Considerations for Design
2 6
Limitations
7
7
Power Output
10 21
24 28 31 32 32
Practical A. 8. C.
33 35 36 36
PART Two: I
APPLICATIONS Water Pumping A. 8. c. Pump Selection Attachment Piping Applications Sample Calculation Criteria to Wheel
36 46 55 57 60
II
Other
An Easily
by Richard
Constructed Burton
Piston
Pump:
65
69
LIST OF TABLES Table Table Table Table I II III IV Stall Torque per Foot of Width Torque 12 14 15 (hp.) 16
Horsepower Output for a Constant Wheel per RPM per Foot of Width
Water Power Input to Wheel per RPM per Fact af Width to Maintain Constant Torque Flow Rate in Imperial Gallons per RPM per Foot of Width of Wheel Required to Maintain Constant Torque Estimated Constant Maximum Output Horsepower for Input Water Flow Rate Condition Flow Rates for by Each Bearing Required for
Table Table Table Table Table Table Table Table Table Table Table Table
19
20
27 28
Standard Pipe Sizes for Use as Axles with Bearing at 12 inches from Wheel Edge Estimated Friction Factors Velocities for Pump Rod to a Crank on the Wheel
31 39
40
Peak Force on the Pump Rod of a Piston Pump for Various Bores and Heads Volume of3Water Pipes (ft ) in Various Sized Delivery
41
42
Inertial Force per Inch of Stroke for Various Volumes of Water at Various Pump Cycle Speeds Horsepower Required for Water Pumping at Various Flow Rates and Heads Quantities of Water Pumped per Stroke Various Bore and Stroke Sizes for
43
45
47
LIST OF FIGURES Figure Figure Figure Figure Figure Figure 1 2 3 4 5 6 Schematic Schematic Schematic Side View of Bucket Shape on Wheel Mechanism Pump
9 11 48 51 52 54
Schematic View of a Trunnion-mounted and Crank Schematic Sc).ematic Pump Rod View of a Scotch Views of a Suitable
- iii
PART ONE:
I.
INTRODUCTION Supplying power to many remote customary distribution locations methods in the world is either from central economically will
using or will
be many years
in coming. locally.
Power,
Various expenditure
commercial
is marketed, cost
capital
is beyond
the capability
of many potential
been expended
of Technology
amounts of power in remote involving power. the power is put the natural categorized. the development
to provide
sources Among
can be utilized
are fairly
readily
Falling Animals Sun Wind Fossil Nuclear Organic are free their
water
fuels fuels waste and renewable in the sense that From continually is attractive. by using operating From
future
usefulness.
a choice
capital
cost
consideration natural
hydro-power limitations
may be very
Sun
Furthermore,
for limited
solar
power use is presently directly continuous is being the world. Whatever formed, if as part food
specialized to useable
of organic success,
waste
experimented
varying
in several
parts
occurring
energy,
it
be utilized. falls
categories
3. 4. 5.
resources maintenance
the machinery
must be portable
II.
FORMULATION OF THE PROBLEM In the absence of a specific was taken request from government on the obvious the design of mechanical is the generation "Other Applications" or any outside abundance of for One
body,
available
possibilities power.
application under
reasons
mentioned
-2-
this
However,
villages of drinking
located
manual has been the pumping of potable The project, also. thus, Several
to a village.
were decided
locally
of inexpensive components
materials
expensive
construction details
of
only
techniques. 3. Since cating the installation a probable if was likely shortage any, would of local to be remote skilled (indi-
tradesmen) and
have to be minimal
should
repair,
if
any,
could tools
out on-site
parts easily
of safety children
with
the not
not/would
the
feasibility likely
of
using
the
of machines
but none,
for creating
mechanical with
sources,
known
techniques wheel.
requiring
so low a level
Water
wheels
are
parts
of
the in
world
now.
and vary
design wheel
who has the separate technical short than fashion of life adequate
Wwever, models
abandoned
that
seems desirable of
an objective sizes
a design specific
required
design following
based
on sound to et
principles.
as an attempt
that
consists SP that
of buckets-to buckets
hold
the
in about flow.
and axis
and frame to
or breast tangent is to
the overshot
wheel,
brought the
wheel, until
partially
filling before
buckets
dumped out
somewhat -4-
reaching
lowest
the wheel
more or
the buckets and then again being dumped near the Typical efficiency
50% for
to wei1 over
the breast
concentrate
power of
on the overshot
output per time is the dollar
wheel
a6 being
or per expected
the
most
likely
choice or
to give Blax
per manhour gating against
pound
of machine, Miti-
based need
a more complex
vay with
at least
overshot
wheel the
where outlet
the water
as the
in
as far wheel,
above of
course,
may be merely
stream
of raceway
local
necessary. is
rainfall for
spectacular, of device.
would protection
be a major is the
consideration leading
any type
a channel channel
to the
water
inlet
to
Since
probably to
be required employ an
a suitable installations.
location
&eel
can be found
installation channel is
that
overshot diversion
impossible, to use.
the undershot
straddling
simple
consi
eration ich it
overshot
wheel
is
the
in the stream.
tends to get flung
the water
into the tail-
over witbout
the
catching
Secondly, in vhich
there trash
usually
the
tight
spaces between
Somewhat
-5-
closer
fitttig
to service usefulness
roughly as a power
between
source
5 and 30 rpm.
for electricity
Consequently
generation
or
because from an
of
involve problems,
increasing
complexities
and maintenance. when the wheel is utilized for powered require driving by only
The slow speed is advantageous certain hand. fractional lished course, placement villages be adapted course, where. Devices of this types Coffee of machinery
hullers
already
and rice
hullers
any speed.
pump.
The positive
a wheel
- maybe thousands
capability.
The
to the wheel.
As an example,
breast
of 16 ft.
diameter rate
of 28 cubic
of water -6-
had an estimated
output output
of
18.5
(calculated
at
of
100%). than
Actual 10 hp is
on that
be less
(7.5
in
kv).
the
A 3 ft.
constructed
by the
author
fractional
horse-power
range.
is worth emphasizing that a stream skills. that will a useable allow, water with the
once, almost
it
anywhere
and elementary
carpentry
Iv.
THEORETICAL CONSIDERATIONS
Stall Torque torque capacity of the machine, ignoring
A.
The stall
effect
of the water
impinging
on the stalled
buckets,
calculated
summation
depend
from the bucket configurations on the skill on the criterion in the buckets criterion Buckets also
which
in turn
depends
used in the 18th and 19th of the builder. of maximizing while required recognizing increased
on this
construction
complexities. Fig. 1,
of the bottom
of the bucket
was typically
where that
configuration
It
is
three
of
the of
capacity
wheel
t,
width,
w, i.e.,
width,
defined
1.
as t = (outside
diameter
- inside
diameter)/2.
See Fig.
of
the
annulus design
width,
t,
to are
the
outside
radius,
r,
is
to wheel values
as there
practical
to the ratios
which
may be employed.
In this
<t/r
per
For smaller
is considered
be practical.
there is
the buckets
insufficient
each one as it
race
exit.
Also, of water
since
the torque
and power depend upon having possible increases The result distance total is from the wheel that weight if more
increasing it increases
is better to values
In this that
components for
economically wheels
to have t/r
on wheel
width
l/2
of structural that
can be estimated
equivalent
of approximately
of the buckets
the
Figure
1.
Schematic side view of bucket Upper: Flat bottomed bucket. Lower: Straight sided bucket.
shape.
-9-
doing
useful
work in
on the
wheel solid
is of
l/4
of
be contained I.D.
an annular of the
dimensions
and width is
wheei.
The actual in
weight Fig.
of the water
of spillage
as shown
schematically
as they
race. quadrant
If
the stall
correction
design,
could
if
refinement
necessary.
Results Blank
for
spaces
wheels
are
dimensions ratios
are given
1. above. of
outside
information given
to use be pre-
in tabular
B.
Power Output Power output the rotational is sufficient keeping with inlet is the product of the torque on the output shaft that and
there thereby
the torque
increases
linearly
speed. water
where calculation
there
an unlimited limit to
an upper
can be expected.
- 10 -
Schematic view of water Figure 2. hatching indicates water remainin in this paper.
distribution in buckets.
TABLE I Stall Torque Per Foot of Width (ft./b) (No Allowance .05 < t/r c 0.25 for Voiume Consumed,b+BucketWall Thickness;
only)
Diameter 8
(ft.) 10 14 20
20 30 40
40 55 70 95
95 ?30 160 240 300 235 300 435 555 655 775 365 485 695 905 1080 1270 1435 1850 2220 2620 3300 4000 2910 3840 4660 5560 7190 8750 10100
10 12 16 20 24
19
12a -
output
of tidth
horsepower output
speed in rpm times the width of the wheel in feet. is the maxlaam power which the wheel could
It the
if
it we&
100% efficient.
weight, for
is calculated
rate, is
waters
in
volume flow
This entry
Table
comparison.
power that
As
rpm per
of wheel. full
rate IV.
is
required in Table I,
to keep
and is
volume for
occupied
later if
by the bucket desired. The lower tailrace datum. that ciently wheel side
can be corrected
of the wheel.
permission for
without
raceways
interfering
a significant It
velocity
effects
accurate 2.~3~error
to estimate thereby
as the
be on the conservative
anyway. efficiency values for the wheel the ratio power input using the assumptions
can be found
by taking
for
the narrow
annulus
annulus
wheels.
As mentioned
give efficiencies
previously,
better
and constructed
wheel
will
- 13 -
TABLE Ii wer Output for a Constant Torque-Wheel +mtz RPM per Foot of Width
Outside 3 4 6 8
Diameter
(ft.1 10 14 20
1 :1*-j:
- 14a -
TABLE III Water Power Input Horsepower to Wheel per RPM per Foot of Width to Maintain Constant Torque.
Outside 4 6
Diameter 8
(ft.1 10 14 20
2 3 4 6 8 10 12 16 20 24
.0364 .0510 .0646 .0980 . 128 .092 0.119 .176 .230 .277 .316 .143 .189 .280 .368 .448 .537 .568 .740 .900 1.08 1.39 1.73 3.13 1.52 1.85 2.23 2.94 3.64 4.26
a.--
-,-t
-.
- __ ---
15a
TABLE IV Flow Rate in Imperial Gallons per RPM per Foot of Width of idheel Requi.red to Maiataia Constant Torque
Diameter 8
(ft.1 10 14 20 r
2 3 4 6 8
10 14 18
13 18 24 34
20 28 37 54 70 39 50 74 96 118 137 48 62 93 123 149 177 123 175 216 255 342 404 190 254 312 373 488 600 706
to
12 16 20 24
- 16a -
modest value
the result
of not
conthe
below
simplifying
accurate.
1) it
gives
conservative be assured
every
reader
will
sufficient
amateurishconstruction. than the required a stream in that to fill of limited the torque each bucket size, the
now is a quadrant is
the assumption
of one annular
V, in the quadrant
Q/4N
where
Q = volume N= speed
flow (rpm)
rate
(ft3/min)
of water
in the annular
quadrant
at any speed is
then
P = density
I3 = gravitational With units from this in feet, annulus pounds, working is and minutes,
hp = 2,~ NT 33,000 where x is the distance T = pgvz = PeQ;Z 4N of the annular - 17 quadrant from the
to the centroid
rotation
axis.
It is equal
to average
diameter,
Dav,
of
the
annulus
Therefore
hP = 2nHPgQDav = PgQDav
QirrNx33,OOO The power is independent of It 66,000 the is speed. because that outside under the The efficiency the the output is power drops Potential of water to the constant input outside the is a off for same
as calculated
function wide output of
diameter, a fixed
efficiency
annulus from
operating
50% nuiximm
Power under is
constant
flow V for
conditions likely
for
various
diameter rates.
wheels
shown iu Table
for t/r
attainable
flow
shown are
= 0 and should
be corrected
entries practical
of the with
prototype
150 gpm, gave output agreement with where the values flow rates
are left
Upper bounds
from Table
On the assumption
- 18 -
TABLE V Estimated Maximum Out@ Horsepower from Wheel for Constant 50%. efficiency of Input. wheel) Water Flow Rate Corkition (based on
rate 1000
.23 .30 .45 .61 .76 1.06 1.51 .60 .91 1.21 1.52 2.12 3.0-S 2.27 3.03 3.79 5.30 7.58 6' . I 7.6 10.6 15.2 21.2 30.3 91 .o
Correction
factors
for
various
values
of
t/r:
to
be multipl
ied
by above
values
to yive
correct
power
ratings
t/tcorrection factor
2.05 0.98
0.1 0.96
0.15 0.94
9.20 0.92
0.25 0.90
RATE (IMP. GAL/MN) ADJUNCT TO TABLE V Be sure to refer to Table V and the text instructions on use. - 19a FLOW
for
TABLE VI Upper Limits on Useable wheel width Flow Rates for Various Size Wheeis velocity in Imperial Gallons Per Minute (assuming
= 3 IO.D.1
and peripheral
Is 5 ft/sec.)
Outside 3 4 Rk%4at 32
I z I
Diameter 8
(ft.
1 10 14 20
6 5 ft/sec 16
peripheral 12
velocity 10 7 5
24
2 3 4 6
8
1000 1400 1800 2600 3400 1900 2400 3500 4500 5500 6500 2500 8000 4500 6000 7500 9000 6000 8500 10500 12500 17000 20000 9500 12000 15500 18500 24000 30000 35000
a wheel
of width
less
and to operate
choice) for
it the
at
(completely
quoted These
indicated
under
in Table
The upper
limit
will
operate
de-
slings
the inprimarily
This
depends
upon the speed and radius bucket configuration quoted x-locity based
upon the
the larger
the
peripheral In summary,
velocity the
may be as high
as 8 ft/sec. speed cur.ve that for fixed flow one can expect Linearly the buckets flow, then are
rates:
from zero
speed up to the speed at which filled by the prevailing significant action, of the
be completely
of water decreasing
in proportion
square
C.
Bucket
Design bucket design is taken shaft. to be that The upper which limit produces to this the condition
The optimum
greatest
torque
on the wheel
- 21 -
fill
completely
at the
top,
carry
the
no spillage
to the bottom
buckets, as they
where
they
by carrying
There are broadly straight with gential process respect emptying bucket sided
two styles
1.
In the
bucket
the limits
makes
to radial
horizontal) is not
water. until
complete carries
bottom
This
some water
up the
is then horizontal. that the greatest at the of various the its cen-
is acting buckets
distance
the optimum.
While
amount of water,
While
of water
at 9Oo after
by this
- 22 -
shape is ly
is
about
than the
for
the filling
bucket,
the
compensated
early
on emptying,
of the
20
inclination from
length than
I.D.
tangential at 90'
a 30'
the weight
to about cannot
such as
the
a figure secondary
be compensated
filling
by the
effects
This
graphical
technique, wheel,
no additional that
shows
the assumption
rive- an upper
quadrant
is a reasonable
estimating be kept
significantly
chrnee
the is to
of 20.
The purpose
t:i2 iucket.
decrease
Its
use is
but
the
builder cated
width, saving
of this
is
of the wheel.
I cannot flat
the
of efficiency
bottomed
seems
23 -
f,~
,,a,
.I
_.
8.1
_I
hard
to
imagine
as much as ten
percentage
points.
Historically, as far
bucket
shapes
varied
considerably.
They were,
emperically.
(In a historical
or "by educated guess-
sense this
work").
By the
engineers,
carpenter-craftsmen,
the problem
decline). circa bucket 1850, side
water
wheel's
manuals in general
wheels
of 45'
were
were efficient
recommended than
- a choice angles.
which
can easily
smaller
in close
in use
agreement
in the
with
the design
I know are
U.S.
of
buckets
wall
very not
material. thin
over
wall
figure
10% of annular
bucket would
material.
Typical in.
values thick
for
the
wheels
buckets
on a 3 foot wheel.
buckets
on a 14 foot
itself
the
has only
bearings
or sliding
part
subject
to Standard
the axle
esign
is covered
any machine
In
as is discussed
the value
is questionable.
weather-proofed
- 24 _
ball
or roller
and complicated
to satisfy
the initial
Bronze bushings
but
suitable
shaft both
material present
would
lubrication
wooden bearings 1. 2. 3.
the best
parts.
for
conditions vitae,
kock maple,
and various
substitutes others
distribution,
be expected departments,
to be when
in a position
to make useful
suggestions. In the absence harder, of any specific knowledge, the general rule is "the
the better". of allowable wooden bearings vitae) for loading would based on experience be around with 75 psi (for with oak) surface for commercially to 150 psi parallel use. to
orientations
the sliding
to the grain If
and about
those
loading
be about
- 25 -
parallel
to the grain
usage. pressures
It will
to be seen what the wear resistance structurally to diameter the figures ratios given
of bearings to be about
reasonably sizes
be expected
unity for
basis
of the bearings
operating
maximum output.
An allowance that
the weight
of the wheel
is made on the basis equal gravity Table width product of course the shaft attached the Table from Table attached. different different, VII to the volume
the volume of wood required carried at stall in water and that is about
is approximately the specific unity. per foot is then in feet. of the This
of water
of wood operating
of wheel.
is
important
for
the purposes
of determining where
the machinery
In this sizes.
apparently
we usually
the size it
by the larger
to support
of 100 psi
and L/D = 1.
Values
the largest
reasonable
bearing
loads.
- 26 -
TABLE VII Approximate W&k&t (per foot of width Carriedof the by- Each.Bear.ing wheel) (lb.1 Excluding Loads Due To Attached Machinery
Outside 4 t(in.1 2 3 4 6
8
Diameter 8
(ft.) 10 14 20
I tG w I
24 35 44
32 47 60 86
50 70 89 140 180 95 125 185 240 290 330 120 160 235 305 370 445 335 440 530 635 820 1020 470 675 765 920 1215 1500 1760
10 12 16 20 24
TABLE VIII
-imum Bearing
Diameter
Required
for
Various
Loadings
(in.)
Load (lb.) 100 Parallel End Grain Useage Useage 1 l/2 200 l-1/2 1 500 2-l/4 l-314 1000 3-l/4 2-l/4 2000 4-l/2 3-l/4 5000 7 5 10000 10 7 20000 14 10 event larger may be location bands in (sum
on wood.
the bearing
size,
a "built onto
is built O.D.
is the necessary
to the cylinder.
The criterion
case is that
of the diameter
the square
in Table
and grain
for
of,
suitable
main-
tenance,
in bronze
mounted suppliers)
from hardward
Proper
problem additional
is usually initial
maintenance
can be guaranteed
E.
Shafts Shafting may be wooden or steel. material The diameter is of course of the wheel. dependent Minimum
upon which
shaft
diameters
metal
d, may be estimated
shafting
for solid
In
this
equation sidwall
of
where
shaft.
in the
It can be estimated
Table VII side for wall the the to shaft the that
as
the
wheel) of the
distance In is of the
wheel of
keeping
to locate (Note
as close cases,
on the bearing, It
the
from to
Table the
distance wheel 1s
along
from
point
attached.) T is is It the torque from acting Table 15,000 used in I. psi the on the S is for shaft the and a conservative shear shafting 1.) stress estimate of the metal.
found is
allowable steel
around is
.ordinary
and pipes.
(13,000
example
in Appendix
For meter
solid of
wooden the
shafts
are as the
used
and the of
dia-
two results
diameter
- 29 -
d3 = 16T
bending stress
If
wood is used it must be sound and free from longitudinal like a pipe, the equation to determine
is:
d3 - 16 12M + T2 aS (1 - k4)
where R = Ratio of inside to outside diameter.
of
0-D.
are
for
For
bearing of
tabulated bearing is
centre pipe
from
the
standard
IX automatically from a wheel VIII. be given pump only to be size Table for IX of
allows
such
torque
that
expect
only
all
ine
the,loads given
serve the
final
be checked
When making
substitutions, to use
it
is penaissable
pipe.
smaller
- 30 -
TABLE IX
Minimum Standard Pipe Sizes
for
Use as Axles
with
Bearings
at 12
inches
Bearing Pipe load (lb) (in)
100
I."
1000 c II 3
2000 4"
5000 * 6"
Diameter
11/2"
with
these is will
figures that
bearzng or solid
diameters steel
obvious need
pipe
shaft, wooden is
to be of
up type
An alternative
to
to use a shaft
size.
selected
the
needs
the bearing
(and heavier)
than required
necessary
shaft
the
diameter
and then
of reducing there)
at the bearing
In
location
either of pipe
a piece
some similar
in the bearing.
F.
Minor
to meet specific
requirements. which
have been based on an achievable consideration affect onto the the wheel of in
is readily
an overshot
There
The exact
is a function
- 31 -
1.
flow
rate
which
affect
the inlet 2. the bucket which onto Exact its calculations nature
sidewall
angle
velocity comes
how smoothly
for
a machine inefficient
which
by
very
as this. in
Let it
be sufficient tangent
approximately
V. A.
PRACTICAL CONSIDERATIONS Materials Most wheels are wood, for cost, or course, selection availability choice though they need not be. material Among
the considerations ease of working, carpenter latter. information probably Builders as a likely varies widely
of the proper
perhaps this
the
Others section
consider
material. around
is convenient Because
to work with
the world.
grades
a doubtful painted,
continuously when it
or when a relatively
short
is anticipated
- 32 -
Regarding logical it
the choice
framework
to mount
probably
would
other
materials. fairly
The species
listed
durable
under
constantly
wet conditions
and
first
to be considered.
B.
Techniques sufficiently skilled knowledgeable is intended to build a water wheel will probably
details. necessary
to select
overall
prevailing
a few general
may help
the reader
some pitfalls. of the wheel sides to the shaft, whether the sides If a steel (if are shaft
Attachment
in many ways.
such
is no further
the spokes
the bending
in the spokes
must
as to break with
the spokes.
The spokes
the bolt
bending joint.
a distance
of the outside
diameter
of the wheel. - 33 -
on a 12 foot
&eel,
and to
spokes
attached
ring)
to a flange
by one, spoke.
by the
2 bolts
flange
side plate
a foot
(annular apart
bolts
should be about
if the
on each
Alternatively
annular
spokes
are as with to
quite
rigid
to
2 or more bolts,
separation
the flange.
A of
the wheel
at
pairs
of
spokes, at and
(one right
crossing or noughts
crosses
square annulus.
lines
attached
the wheel
used should
Resorcinol
be highest glue is
quality probably
glue
for
obvious
choice.
Bucket
attachment wall
to the side
wall
may be made by either edge or by attaching the buckets wall This in that to. the
to receive
simpler
can be must
the I.D.
the buckets
be made complete
and non-leaking
the sidewall
is attached.
is is by no means impossible If a solid the bucket to let sidewall bottom is used, into water
but may be more difficult. holes should be drilled the bucket side wall adjacent to
any leakage
would
- 34 -
be used.
Spokes offer
several
techniques
the truly
amateur
builder.
C.
Maintenance The wood used may be painted This will obviously if desired, extend or varnished the life for a protective Periodic coating. re-
painting,
grounds. is a luxury.
durable
painting
is probably
cheaper
or repair major
of the wheel. problem figures drop block is is in bearings. in Table the wheel will VIII from its for Generous but allow-
maintenance
ances have been made in the will still wear. This will the bearing
original this.
compensate
completely
worn through
is a simple
totally if
with
lignum
vitae species,
or commercially we can not make should Oils be made and the wear help.
statement.
the bearing
as needed.
and might
- 35 -
I. A.
WATER PUMPING Pump Selection The only type of pump which is a positive is reasonable displacement pump, lift to use at the slow speed pump. They are called by
pump, piston
pump, windmill
by brand
commercially
head,
durable,
of workshops.
size,
stroke
length
of wheels.
frequency
cam or a gear
of the pumping process, One for only very acting simplicity simple
discuss
simple
or double acting
pumps there
One single
pump attached - 36 -
to the wheel
speed surges
takes the place cylinder. is
on the wheel
only half During the this
because
time. filling
that
actual
pumping filling
wheel
half
is spent
less
considerably
torque
required
pumping.
can be partially 1.
two single
by using pumps 180 out of phase so that doing useful work; same effect as 1. one
pump which
has the or
is built of all
acting
of the system.
to a crank
can be attached
line
which do not
nor stall
such variations
can be damped with by using paragraph. sufficiently pump expert ideas given
in the delivery
be included be consulted
manual
should for
the design
the user's
In general velocity,
of the delivery
and the
When speaking
- 37 -
and design It
requirements,
is pres-
is a means for
of water
in a vertical
to produce, to.
The'pressure just it
be produced
were.
a handy shortcut
engineers.
The head required components: 1. the actual exit, 2. friction equation: friction where Table i.e.
pipe and
(vertical)
height
by the
loss
of water
an example
- 38 -
TABLEX Estimated Friction Water 1 Old Iron New Irun Plastic It Pipe Pipe Pipe that ,045 .030 .O25 this pipes, pipe Factors Velocity .5 .040 .023 .017 becomes a major or with for Cool Vater
(ft/sec.) I_10 .038 .Q21 .015 factor in very long pipes, velo.
is evident
in small city
diameter
high velocities.
The water
is a function
of the peak pump piston and the delivery directly and wheel to the speeds. pipe
velocity
in Table
XI for line
the delivery
by multiplying
That
is,
piston pipe
in delivery
times
of thumb,
this
resulting in short
delivery runs,
pipe
velocity
size
determine
required
force on that
is the product
of the area
- 39 -
TABLE XI Peak Pump Piston Velocity (ft/sec:) for a Pump Rod.Attached.DirectIy to a Crank on the Wheel
Wheel Speed (R.P.M.1 28 5 I s I 6 0 10 12 15 20 0.048 .059 .078 .097 . 117 .147 .195 4 0.087 .104 ,138 .173 -208 .260 .345
(in.
1
8
Pump Required
Head
(f-l,)
change 200
in
elevation
and 300
friction 400
loss 500
100
1 l/4
1 l/2
1 3/4 2 2 l/2 3 l/4 4 l/4
area.
Figures
for
force
XII.
No
allowance servative.
so the figures
are con-
are required
to design that, if
as clevis
pins directly
in Table by
the torque
of the wheel
as given
Table
Of
course,
levers
or other
multiplying
devices
are
used,
appropriate
calculations remains
The force
in Table
XI must be adjusted
the change
in crank
the line
is very
large
so that
the pressure
pipes
(ft3)
length
200 1.2 4.65 9.82 17.50
size
50
l3
1.16 2.46 4.38
100
-6 2.32 4.91 8.78
42 -
wY-
.
L
Pi
. a,
. M
0;
0 Y-
L 2.
c i aI c
ln
u-3 E 2
0 M
- 43 -
This
inertial
force At
is
at
just friction
piston is total
its
stroke.
this
delivery start of
pipe velocity
the plus stroke the
Hence to It is
the
force
head force
inertial friction
should
be compared
when the
ponents
designed
to withstand
larger
the
power
required
to accomplish
pumping
under
of head, XV for
flow steady
rate flow
Table
explained
below.
required
to the pump
conditions
of a piston required,
multiply
pump, by 2 for
or by 1.5 for
an estimate
of the size
of wheel
As mentioned
near
in smaller disexceeds
their
capacity. torque
advantage
so long
capacity
of the wheel
decreases
- 44 -
V in -u (0 al I
0 P 8 N-l 8 d
in 5 .
-0 Fi
Ln 6.
In 7 .
i .
P-l .
In P M
L!? u .
2.
Ln .
u-l z. s.
Lrl c .
N.
2.
Ln .
2 5 .
UT N 0
Y
0 z
s: F 0
Ln .
K .
In
5:
G 0
Ln P v-$ . .
2 a 0
F 0
2 2 . .
t; AZ<
30 0 LL
V
in
. E .I
?I
0 Ln
0 0
0 ln
0 8
0 2
45
the take
mass of place.
the
wheel
is
such
that
stroke bore
slightly sizes.
with
the
design
of
manufacturer
figures
XVI.
can be taken
These are
in Table
B.
undue side
bucket.
Straightline in textbooks,
mechanisms not
are desto
and discussed
endeavor
Ihe books seldom mention arise compare when trying advantages along to use and diswith
the practical
such mechanisms. advantages. the advantages A slider device prevent justable plate through with I will
mechanisms
is attractive
as a simple to ad-
the advantage
of requiring
no special
bending
Stroke shaft
a flange axis,
at various pin
which
stroke
have differrotational
on the crank
pin
resulting
in non-uniform
wheel
- 46 -
TABLE XVI
Qsanrit;es
ot
Water
Pumped per
StroKe
Various
Sizes
Stroke
(in.) a
10
Bore
'jn.)
2$
12
* 4 I
1;
1;
2 2; 3 3;
4
- 40 -
(unless acting
compensated
for
by other
pumps operating
to an extent axis.
mechanism. during
however, stroke,
increases
necessitates length)
moving to maintain
bearings
(increasing pressure
as with
the
symmetrical
pressure enough
presents
a problem. to water
fittings
There
and clevis
is a potentallowable on
problem
tolerance pin
advantage
compared with
method
accurate,
of attachment
to the wheel
shaft
(as on trunnions),
- 49 -
pump rod end to the same kind pump oscillate Fig. 4). This side to side
of crank
pin
as before
and let
as the piston
the plane
at both
but fortunately
pin which bearings ation, these slider problems jection connection intends ing this
slides
in.
The
loads
the pump rod loaded bearings slider this would crank technique
be smaller mounting
than
on the
so that
bearing ob-
A serious a flexible If if
mounting
method
from the pump to the distribution to build particular with his own pump, which arrangement, the trunnion pipe would
plan'to axis.
to oscillate
connection
be the
most durable. The scotch require allow. yoke mechanism (See Fig. machining is 5) is than simple available danger and direct equipment of excessive This is not but may will
the potential
a suitable
mechanism
conditions.
- 50 -
_..._., _..-_-..._... \ \
51 -
J u. d. I
0 ::
m u-4
0
52 -
alternative.
It
would be very
absorb in Fig.
location plate.
would
mounting
case allows
piping
to be attached
to the pump. A pJrnp bought ready made with aligned a handle can be attached on the wheel quite simply
by a rod suitably
a crank
and velocity
calculations
motion
linkages
are easily
They
of simplicity
and durability
are discussed
in books
on
line
motion over
seldom
to run a cable
a pulley
attached
An alternative
approach
is to link
- 53 -
Wheel
shaft
Pump rod
Figure 6. by sliding
Schematic bearings
views ef a suitable cam activated pump rod. Straight top and bottom. Other simpler arrangements as described
line motion of the pump rod is assured in the text are generally~preferable.
crank
to a sector
of a pulley rotates.
the far
sheave enough
always
tangent
to the
to provide drilling
of the drive
long
pumps located
at a considerable provides
from
instance,
power generated
at a stream
C.
Piping
r
distribution elevation,
the water
to a higher
is usually
such as buckets
on an endless
belt,
etc.,
endeavor
the designer
choice. in long (now around are greatly lengths 200 meter) reduced ft lengths to
is available
of couplings which
and joints
compared typically).
pipe
(21 l/2
is flexible
in strict
engineerto damage
ing terminology)
is more susceptable
- 55 -
rocks,
pig hooves,
etc.
Its
strength normal
is rated
to support
300 foot is
conditions. however, It
strongly
is not
rocky,
from suffering
rock
damage.
used as a bed and cover. can generally it simply be laid on the ground It will with rock more than
through plenty
support
margin.
high,
system required
can be made by the techniques Prices grades for the two types but for cheaper. bore this
strength may
of polythene
polythene
so that would
losses
are less
than
in long different.
gravity
of a given
100 ft
weighs Therefore,
60 lb while long
100 ft
weighs remote
distance
by hand to even
might other
influence shortcomings. - 56 -
the decision
polythene
in spite
of its
II.
OTHER
APPLICATIONS
While
wate'r
pumping
is an obvious
use for
the water
wheel,
the intention
the possible
Rather,
the wheel may be put. is a possibility reading which this will manual. probably There
are wheel
cheap task
difficulties
are the speed step-up Low voltage auto generators Simple for D.C.
or alternators)
flywheel-ring-gear reasonable diametral of about continuous amps for cost. pitch l/2 h.p. output long
ring which
have a lower
therefore,
from a 12 volt
periods
12 volt
being
Electricity
57
is better
left
to the higher
speed devices
which
Turbine
of a centrifugal
2.
will
not
easily
with joints.
old
and their
the use of one universal sides. faster For a constant and slower
not give
constant is
speed,
the output
depending
are small
be tolerated, wheel
constant
from the front must be used, other. Flexible torque Solid require shafts carrying shrifts
each to c,'mpensatc
available
torque
over considerable
distance be expensive.
but
bearings
support
- 58 -
Virtually could
is currently
hand-powered the
attachment
from machine
be any significant
problem.
- 59 -
manual
to water
pumping.
The decisions
the bounds
example
made for
village,
15 miles a wheel
One of the possible below the level 750 feet drops quite is about
in a stream steep
The hill
is quite
about level
between
second
(estimated That
to travel
distance).
to determine
300 people.
Each person
according experience
the water
shows that
would quoted
A minimum of
10 gallons
scheme.
Let us or of con-
to allow
of population
- 60 -
1.
Total
water
requirement
X
in gallons x
storage
at the village
draw at peak hours. 2. Power required 250 gal/hour some losses steady 3. to meet this at approx. pumping head rate from Table ft. 4 h.p. XV. rise +
400 ft.
as yet uncalculated)
requires
under
conditions. on the type for of pump arrangement 2$ times acting that for used, the wheel acting for 2 will pump,
Depending
a single that
double
pump.
Assuming
case of
1 single
possible distance
wheel
operate
12 rpm or less
VI).
The stream 10 ft
has a flow x $ ft
x 1 ft set
or 5 ft3 x 6% gal set ft3 At 1800 gal/min from an 8 ft. we should wheel (Table be able x -60 set min to produce less = 1800 gal min
2 h.p.
at least upon
V) or slightly
depending
- 61 -
t/r
values
500 gallons
of pumping
to the village
have been impossible. 12 rpm and 4 ft. width (maximum usually the annulus width used neces-
we can estimate
(Table
1% h.p. needed I2 rpm x 4 ft wide In the entry lus widths under listed
= 8 ft. will
0.025
h.p.
diameter provide
now know we can make the wheel and the annulus It width
3 in.
an 8 ft. required.
wheel 6. If
do the job
the wheel
12 rpm and the pump is directly per rpm with connection no added suggested per revo-
so that (for
be one stroke
250 gal/hr x
hr 60 min
min 12 strokes
XVI that
9" stroke
- 62 -
7.
in the pipe
to 10 ft/sec because it
then
the
than the 4" pump) is related the pump size. 12" stroke section From Table
12 rpm is
.624 ft/sec.
area must be approximately .624 x 11 (3Q2 -104 x 1 = Pipe area 1" diameter iron = .64 in2 pipe. to withstand 1" pipe the presis used,
This 8.
would
require
a nominal
The pipe
would
sure of heads exceeding the actual The friction friction Thus the total peak velocity head loss loss =
a nominal 7 ft/sec.
forces =
2 in.
because
is obviously size
substantial
the cost
1850 lb.
of 6" is required
- 63 -
the machine From Table of the wheel 10. To allow adding annulus. about fairly shaft for
is 925 ft/lb. 1 we see that if it this is well wide. expansion of needs without I would loads select are a 4" VII) within the capacity
is 4 ft.
reasonable weight
future
(Table
each.
the bearings
found
d Any solid
steel
shaft
larger
than
this
will
be satisfactory.
- 64 -
APPENDIX II An Easily Constructed by R. Burton This pump was designed by P. Brown (of the Mechanical of Technology) Engineering with a view Workto up Piston Pump
shop at the Papua New Guinea University manufacture using fittings To avoid pipe in Papua New Guinea.
Consequently
equipment.
Most parts
at any plumbing
to bore and hone a pump cylinder, Provided care is not is taken to select
is used.
damaged during
construction
system
c c
satisfactory. diagram, silver the ends of the pump onto the pump but avoids
As can be seen from the cross-sectional body consist cylinder. of copper This pipe reducers
soldered
the use of a lathe. If a lathe is available, a screwed for end could simple be silver soldered to the
upper
end of the pump to allow of the pump consists it (see diagram). with
disassembly. P.V.C. bucket flange with holes above valve. leather, bar is a die.
through
is attached
and together
the holed
type
a commercial
is not
ends using
2 DELIVERY PIPE
OLDER
.---I
6
Wl-ilT
NUT
6x36
tiOLES
Sl LKR
SOLDER
ii
G RUBBER RING
66
nipple
is silver
soldered pipe
reducer
of the
to be attached. P.V.C. pipe is used as a any fixing A &" screwed the foot valve. since flange This brass plate. plate
This
require
copper forms
reducer. for
the plate
up the bore of the pump by three wall of the pump above the valve in to prevent pump is leakage
in through
These pegs must be silver A parts with Parts 1 only 2 only 1 only 1 only 1 only 1 only 1 only 1 only 1 only l/8" list for list.
soldered
or movement. together
a tool
copper
tube
4" to 1%" copper 1%" galvanized +x" screwed %" plug Q" P.V.C. Rubber piece '0' flange ring
flange
- 67 -
Hand drill %" Khitworth $" Whitworth Hacksaw Hammer die tap
- 68 -
BIBLIOGRAP'HY Village Technology B Water Supplies: Avenue, Mt. Rainier, Maryland, Areas and (1959) Canada
Village Technology Handbook Publ. by VITA, 3706 Rhode Island 20822, U.S.A.
Wagner, E.G. and Landix, J.N., Water Supply for Rural Small Communities, Geneva: World Health Organization Handbook of Appropriate Publ. by Brace Research Technology Institute, McGill Univ., for
Montreal,
Handbook of Homemade Power Bantam Books, N.Y. (1974) (Complete Paperback) Cloudburst Cloudburst Historical: Banks,
Kees,
Drawings
Water Wheel -
B.C.,
Canada (1973)
J., A Treatise on_ Mills, 2nd ed. London: - Urme and Brown and for W. Grapel, Liverpool
Longman, (1815)
Hurst, New
Evans, O., Young Millwright & Miller's Guide, 13th ed., Philadelphia: Lea & Blanchard (1850). Reprinted by Arno Press, cjo Aris & Phillips, Ltd., Teddington House, Church St., Warminster, England Ewbank, T., Hydraulics and Other York: Bangs, Platt & Co. (1851) Ferguson, J., Lectures Optics and Astronomy, Machines for Raising Water, New
on Mechanics, Hydrostatics, Pneumatics, London: Sherwood & Co. (1825) Calculator, Hartford, Conn.: Summer Sturbridge,
Grier, W., The Mechanic's & Goodman (1848) Hamilton, E.P., Massachusetts: Hughes, W. C., Philadelphia:
The Village Mill in Early New England, Old Sturbridge Village Press (1964) The American Miller and Millwright's Henry Carey Baird (1853)
Assistant,
- 69 -
Lewis, P., The Romance of Water Power Sampson Low, Marston & Co. Ltd. London: Nicholson, Philadelphia: J., The Operative T. Desilver,
(Ca.
1925) Machinist
of Mechanical (1954)
Chironis, N.P. ed. Mechanisms, (1965) N.Y., McGraw Hill Tuttle, S.B., Mechanisms N.Y. Wiley (1 967) Black, P.H. & Adams, O.E., N.Y. McGraw Hill (1968) Faires, London, Hoyland, London, Parr, N.Y., for
Linkages Engineering
Controls
Machine
Design
V.M., Design of Machine Elements Collier--Macmillan (1965) J., Engineering Cassell (1968) Construction and Materials Design of Machine Elements
Rothbart, H.A. ed., Mechanical N.Y., McGraw Hill (1964) Construction: Bayliss, London,
- Timber Design and Construction (1956) N.Y., McGraw Hill Durban, W., Carpentry Chicago, Am. Tech. Sot. Keeling, London, (1970)
Eastwick-Field, J., The Design and Practice London, The Architectural Press (1966) - 70 -
Andrews,
H.J.,
An Introduction
to Timber
Engineering
Oxford, Materials:
Miner,
Pergamon
(1967)
N.Y.,
D.F. Wiley
eds.,
Handbook
of Engineering Timbers
Materials,
- Properties and Uses of Papua New Guinea Boroko, PNG, Dept. of Forests (1970)
Berzinsh, G.V., Snegovskii, F.P., Skrupskis, V.P. Plasticized Lignum as New Anti-Friction Material" Mashinostroeniya, 1, Jan. 1969, p. 45 O'Conner, J.J. et. al., eds., Engineering (1968) N.Y., McGraw Hill Fuller, D., N.Y., Wiley Theory (1956) and Practice Standard Handbook
of Lubrication
for
Callahan, J.R., "Lignum Vitae Wood for Processing Chem. & Met. Eng. 51, May 1944, p. 129 Atwater, K. "Lignum 1932, p. 1 Verney, Londcn, Pumping: Southern Cross Machinery Co. Catalogue Industrial Enterprises Ltd., P.O. Box 454, Aust. 4350 Sidney Williams and Co. Catalogue P.O. Box 22, Dulwich Hill, NSW, Aust. - Pumping Manual Trade Morden, Surrey: and Technical 2203 Press Ltd. Vitae Bearings" Trans.
Boat Building
Toowoomba,
Qld.,
(1968)
and Application
- 71 -