Prime Head of Centrifugal pump using automation

A Research Report
Present to
Engr. Karla Madrid-Khalid
Department of Electrical Electronics Engineering
College of Engineering
Mindanao State University
Marawi City

In Partial Fulfillment
0f the Requirements for the course
EE 198 Xx (Research Method)
1st Semester, 2020-2021

By

Randi T. Ambor

October 2021
Chapter I
Introduction

Centrifugal pumps are used to pump water from reservoirs, lakes, streams and

shallow wells [3]. Centrifugal pumps are typically designed with a durable rugged cast iron

pump body, tough thermoplastic impeller, glass filled thermoplastic diffuser, and a cast

iron seal plate. They are usually rated at 1 HP230V and can be used for applications

requiring up to 29’ suction depth.

The operation of a centrifugal water pump is based on a rotating impeller, which

converts kinetic energy into pressure or velocity that is needed to pump the fluid [10]. As

you can see the nameplate Figure 1.1, the voltage rated available to operate properly our

centrifugal pump is 220VAC single phase or ranged at 220 to240VAC, below the 220VAC is

affected velocity of impeller as well as suction head.

Figure 1.1 The Name plate Centrifugal pump

 Centrifugal pumps are very commonly used by the people of Lanao del sur getting

water from the many tributaries of Lake Lanao and into their homes for domestic purposes.

Unfortunately, it is well known that many municipalities in Lanao del Sur suffer from

power quality problems, especially undervoltage. Figure 1.2 shows the severity of

undervoltage and fluctuations, as observed in the Basak Area, Municipality of Taraka for a

week, between June to August 4, 2021 due to unplanned interrupted blackouts we

measured inconsecutive days at Brgy. Buadi Aro rao, Taraka, Lanao del Sur.

Figure 1.2 Output Voltage Measurements taken in Brgy. Buadi Aro rao, Taraka, LDS between June to August 4, 2021 in 7 days

Since we operate the centrifugal pump around 5AM-9AM, it is obvious from figure 1b that

because of undervoltage operating the centrifugal pump is practically impossible. In an

attempt to alleviate the problem, a generator is often used to run a centrifugal pump.

However, even with this remedy, using a hand pump is still necessary to get initial water

pressure up because the suction of water is very weak due to limited distance of suction lift
and to prevent cavitation [1-4]. “Cavitation” is a term commonly used for a fluid pump. The

word cavitation is a problem not just air bubbles generated by the pump. But, also too large

suction head, too long plumbing run and restricted or collapsed plumbing hoses and so on.

Those are affected the inlet of the pump and pump makes hunger and then cause the

cavitations.

This pump aims to design and develop an automated system that enables the operation of

an existing pump known as Bolzano water pump and also you can see figure 1.1 a

centrifugal type pump has a maximum suction head up to 9 meter or 29’ and 220VAC

voltage operation centrifugal pump despite undervoltage problems in Lanao del Sur.

This centrifugal pump needs to install the water booster before the centrifugal pump for

priming the suction of water. Second, the location of the centrifugal pump is very far at the

source which is estimated at 115-130m the size of wiring is affected due to voltage drop.

Project Objectives

Specifically, this project has the following objectives:

● To prime of Head suction of water without using Hand pump

● To use solar energy harvesting devices to electrify the water booster.

● To automate system to free hand pump

● To implement the prototype for testing and evaluation.

OVERVIEW

Figure 1.3 Simple Block Diagram of the System

This system has three major factors shown above in the figure 1.3 the water

pumping system, PV system, Microcontroller, those are to help prime suction of main pump

also free hand pump.

The system shown in figure 1.3 the water pumping system had two main parts to

automate the water booster (solar pump), centrifugal pump to free hand pump. Water flow

sensors have a dual sense such as accurate measurement, and detection [19].

We will only use detection of flow of liquid, if the water pressure arrives or not the

discharge of outlet port of main pump (centrifugal pump).

The PV system is supplying a 12V battery, we will use this PV system to supply

electricity to our solar pump. However we cannot directly connect the generator 230ACV

using Power supply due to the minimum amount of power capacity.

 Microcontrollers also had two parts such as a water flow sensor, and Songle 30A

230ACV/30DCV, these parts are very important in terms of automation. If we compare this

in human body these parts are considered as thinking as mind, action as hand.
Chapter II
Literature Review

2.1. Head

“Head” is a term commonly used with water pumps [2, 3]. Head has different

categories such as suction head, velocity head and so on [3]. “The suction head includes not

only the vertical suction lift, but also the friction losses through the pipe, elbows, foot

valves and other fittings on the suction side of the pump” [2, 3]. Head to be generated by

pump is determined such as total static head, friction losses for flow rate [8].

2.1.1. Category of Head

2.1.1.1. Total Dynamic Head

The total dynamic head of a pump is the sum of the total static head, the pressure

head, the friction head, and the velocity head. The brief discussion of these terms is

given below in Figure 2.1 [2, 3].

2.1.1.2 Total Static Head

The total static head is the total vertical distance from the pump that must lift the

water. When pumping from a well, it would be the distance from the pumping water
level in the well to the ground surface plus the vertical distance the water is lifted

from the ground surface to the discharge point. When pumping from an open water

surface it would be the total vertical distance from the water surface to the

discharge point, as shown in figure 2 [2,3].

2.1.1.3. Pressure Head

Sprinkler and drip irrigation systems require pressure to operate. Center pivot

systems require a certain pressure at the pivot point to distribute the water

properly. The pressure head at any point where a pressure gage is located can be

converted from pounds per square inch (PSI) to feet of head by multiplying by 2.31.

“For example, 20 PSI is equal to 20 times 2.31 or 46.2 feet of head. Most city water

systems operate at 50 to 60 PSI, which, as illustrated in Table 1, explains why the

centers of most city water towers are about 130 feet above the ground” [2, 3].

2.1.1.4. Friction Head

Friction head is the energy loss or pressure decrease due to friction when water

flows through pipe networks or another cause of friction is due to rubbing of water

particles or against each other to the wall pipe called friction head [18]. The velocity

of the water has a significant effect on friction losses. Loss of head due to friction

occurs when water flows through straight pipe sections, fittings, valves, around
corners, and where pipes increase or decrease in size. Values for these can be

obtained from friction loss tables. [2, 3]

2.1.1.5. Velocity Head

Velocity head is the energy of the water due to its velocity. The larger nozzle, the

slower it becomes, however smaller nozzles the faster become [2, 3].

2.1.1.6. Suction Head

A pump operating above a water surface is working with a suction head. The suction

head includes not only the vertical suction lift, but also the friction losses through

the pipe, elbows, foot valves and other fittings on the suction side of the pump.

There is an allowable limit to the suction head on a pump and the net positive

suction head (NPSH) of a pump sets that limit. The theoretical maximum height that

water can be lifted using suction is 33 feet. Through controlled laboratory tests,

manufacturers determine the NPSH curve for their pumps. The NPSH curve will

increase with increasing flow rate through the pump. At a certain flow rate, the

NPSH is subtracted from 33 feet to determine the maximum suction head at which

that pump will operate. For example, if a pump requires a minimum NPSH of 20 feet

the pump would have a maximum suction head of 13 feet. Due to suction pipeline

friction losses, a pump rated for a maximum suction head of 13 feet may effectively

lift water only 10 feet. To minimize the suction pipeline friction losses, the suction
 pipe should have a larger diameter than the discharge pipe. Operating a pump with

suction lift greater than it was designed for, or under conditions with excessive

vacuum at some point in the impeller, may cause cavitations. Cavitation is the

implosion of bubbles of air and water vapor and makes a very distinct noise like

gravel in the pump. The implosion of numerous bubbles will eat away at an impeller

and it eventually will be filled with holes [2, 3].

Figure 2.1 The Total Dynamic Head (TDH) is the sum of the total static head, the total friction head and
the pressure head. The
Table 2.1 Pounds per square inch (PSI)
Centrifugal pump has maximum suction head of 33 feet [2].However, our centrifugal pump

pipeline from the surface to river is about 55.77 feet which is out of range of head. A long

distance pipeline must have an additional water booster and of course we have to consider

the air tight connection of the pipeline head, in order to prevent cavitation [1, 2].

2.2. Types of Pump

We have two categories of pump such as positive displacement pump, and dynamic pump.

2.2.1. Positive Displacement Pump

Positive displacement pumps are usually used for auxiliary systems

containing oil, however dynamic pumps are usually used for large auxiliary system

water based [14, 15]. “These increase pressure by operating on a fixed volume in a

confined space [18]”.

2.2.1.1. Rotary Pump

There’s the example of rotary pump as follows; these types of pump have

different impellers that emphasize them as their own function and kind.

● Piston Pump-is a high pressure pump, usually used for car

wash. Piston pump has a shaft motor connected to the cylinder

block containing the piston, piston also connected to the

spring. The swash plate tilted at an angle. As soon as the

cylinder block rotates, piston against slide rotates on swash

plate and piston reciprocates on and off, so those pistons suck

water intake stroke to discharge stroke [14, 17].

 ● Vane Pump-vane is connected to the spring to make tension on

and off, just like piston on and off tension using spring. As soon

as the rotated vane water enters the inlet port then, water

traps the vane to discharge [14, 17].

● Screw Pump-have two different gears, inner gear and outer

gear. Inner gear connected the shaft motor and protrude outer

gear however, outer gear protrude the inner gear inside the

center gear. Allowing the outer space inlet port to discharge,

between them is a crescent divider to trap water between gear

teeth [14, 17].

● Gear Pump-have two gears, one is connected to the shaft motor

called drive gear, other gear is smashed by drive motor

allowing the gear rotates, as soon as the gear rotates at ward.

The water through the inlet port, the gear teeth allowing trap

water to discharge the water, the between two gears is blocked

water [14, 17].

● Lobe Pump- is similar to the concept of gear pump, however

the difference between them is propeller [14, 17].

2.2.1.2. Reciprocating Pump

A positive displacement pump used a piston and wobble plate to make

pressure [14, 16]. We have example as follow;

● Diaphragm Pump
 A reciprocating type pump that can be used as fluid operated

Pump and Mechanically Operated Pump. That uses a combination

of rubber and Teflon diaphragm in other words controlled

volume-type pumps [14, 17].

● Piston Plunger Type Pump

A plunger reciprocating type pumps a stationary and smooth

cylindrical slide against to make pressure, however the piston is

similar to the plunger the difference between them is higher

pressure. These pumps are extremely high pressure [14, 17].

2.2.2 Dynamic Pump

Increase pressure by using rotary blades to increase fluid speed or flow

water [14, 18]. And also the other term use is kinetic pump as dynamic pump, we

have a good example as follows;

2.2.2.1. Centrifugal Pump

Can be referred to as a dynamic pump, which is the low level pressure

to high level pressure. Liquid enters the center of the rotating impeller, to impart

the liquid then centrifugal force to discharge fluid [14, 18]. Centrifugal pump is

widely used every aspect and use in necessary [18]

● Water Booster
 PV solar pump or DC motor pump used as Water Booster

Pressure System (WBPSs) to maintain pressure and help draw

water from shallow wells, rivers, ponds and lakes [4, 6]. Water

boosters help suction head to meet the need of a centrifugal pump

to run. The impeller of the solar pump we actually use is the same

as the centrifugal pump.

2.2.2.2. Axial Pump

Its dynamic type pump uses an impeller just like the propeller of a ship, to

make enough speed to gain pressure.

These types of pumps commonly use fluid transfer fluid to another, however the difference

between them is impeller.

2.3. Automation

Solar Based Automatic Irrigation System with GSM Module, this topic is related to

my project studies in terms of automation for example using microcontroller, sensor, pump

and so on, this topic is intended to gather data using automation [5]. However my project

studies are about prime head using automation and we use two different sources DC

voltage and AC voltage to run a centrifugal pump using an automated system and without

need of hand pump.

 Centrifugal pump performance characteristics for domestic application, also related

to my project studies in terms of water booster, and centrifugal pump [12]. However, my

project studies are focused on free hand pumps using automated systems.

2.3.1 Type of Automation

Automated systems are very helpful in this generation. All we have to do is easy

doing so, this generation we have called it is technology age as we have analyzed to

compare to previous years automation is now normalized for user’s.

2.3.1.1 Switch on-off automated Centrifugal pump

To prevent cavitations of the inlet port of the centrifugal pump we have to use

automation using arduino uno and songle relay 30A 250ACV/ 30A 30V controlled voltage 5

VCC. To operate a switch on-off centrifugal pump.

2.3.1.2 Switch on-off automated solar pump (water booster)

Using solar pump as water booster to help suction of centrifugal pump, to prevent

cavitations of inlet port of centrifugal pump we have to us these automation using arduino

uno and songle relay 30A 250ACV/ 30A 30V controlled voltage of 5 VCC. To operate a

switch on-off solar pump. In other words, in order to give enough pressure and free hand

pump.
2.3.1.3 Water flow sensor

This is our base program in order to sense or detect water arriving thru the sensor,

and then gives the signal to our main server to operate these two motors. This is the

formula of our main program as follows [19];

pulse frequency
Water flow sensor= equation 1
7.5

water flow sensor

Flow rate= ; units L/mins equation 2
7.5

Another interpretation or analysis of the formula is using an interpolation method to get

the formula, using the given output of the nameplate shown figure 2.2 below. For example

the minimum sense to maximum sense , flow rate of flow sensor is 1L/min-30L/min, the

arduino uno analogRead pin measured up 0- 1024bit as shown in figure 2.3 below.

Figur
e 2.2 Nameplate flow sensor
Figure 2.3 Flow rate VS AnalogRead
Flow sensors sense only when flow at 1L/min other than below that cannot sense, so using

an interpolation method to get formulas to get the right algorithm. So that our main

algorithm depends on this flow sensor to sense to start switching on and off motors using

Songle 30A.

And this is a formula we get,

29
X= y−1,
1023
Chapter III
Methodology

3.1 Design

Too long plumbing and too long suction head that will affect the inlet of the

centrifugal pump then form cavitation, to prevent that using an automated system with

water booster to assist the suction head of pump and form free hand pump. See figure 3.1

Figure 3.1 Block Diagram of the System using feedback

As we can see in Fig. 3.1 We have two loops to control or prime the head of the

centrifugal pump using automation, such as inner loop and outer loop [7].

The system block diagram represented in Fig. 3.2 below is divided into two parts; one is an

electrical part, and another is mechanical part. Considering AM power Supply to produce

DCV. Therefore, it is the electrical part of the power supplier [5].

Apart from the mechanical, it consists of flow sensor, water booster, and ect. Gives

information to the arduino uno to operate and their output is to start driving a centrifugal

pump to get water.

● Source is providing any amount of energy to give life of any machines as

follows:

▪ Generator this helps to provide enough starting current or voltage in

order to operate a centrifugal pump.

▪ Converter 230 ACV –DCV This is connected to the input to the

generator and output of the switch relay, so that we cannot directly

connect the switch relay onto the arduino to prevent CPU burn, and

the ground of our power supply is also the same node of the arduino.

▪ Size of wire is one of effectiveness of resistance, the smaller wire has

high chances of resistance, and the bigger wire low chances of

resistance. Length of wire is one of effective resistance, longer wire is

high resistance, and shorter wire is low resistance. Kind of wire is one

of the effective forms of resistance, such as copper, aluminum, iron,

and gold. They are different from conductivity or resistivity. Type of

wire is one of the effects of resistance, the higher the temperature the

higher resistance, the smaller temperature the smaller resistance [9].

● Solar Pump (Water booster) helps suction of water to get water and of course

no need to use a hand pump after receiving the signal from the server water
 booster will execute, before that we have to install the foot valve flexible

plumbing properly.

● Water flow sensors help to detect if water will flow or not, then send the

signal to the microprocessor.

● Microprocessor is the main server, after receiving the signal of flow sensor

the microprocessor decides on-off of the centrifugal pump and water

booster.

● Switch relay is used to operate on and off the centrifugal pump after receiving

the signal of the main server.

● Centrifugal pump is also connected to the switch relay, after receiving the

signal from the server, the switch relay will execute then the centrifugal

pump will run.

Before operating the centrifugal pump, the main server send command automatically the

water booster start now until then, the flow of water reach the water flow sensor to start

centrifugal pump and then, after started the centrifugal pump it will automatically 1

minutes to turn off the water booster.

 Figure 3.2 Block Diagram of the system

We have

four main parts using an automated system first, Arduino Uno Second, Water booster third,

water flow sensor and finally Songle Two channel relay 30A 250 ACV/ 30A 30 DCV. These

are automated to support our main pump and provide enough water pressure to free hand

pump. Aside from that, electrical parts such as AC generators and solar panel DCV. Whereas

mechanical parts such as flow sensor, centrifugal pumps, solar pump (water booster),

songle. Those are important to manage our problem solution. The materials we have to use

as follows:

1. Solar panel, battery 12V 6A, Charge Controller 30A

2. AC Generator 2500-3500VA

3. 10# AWG 1 roll, type THHN

 4. 8# AWG 1.5 roll, type THHN

5. Rubber heat shrink 5mm x1

6. Electrical Tape x1

7. Self locking plastic nylon cable tie x1

8. Arduino Uno x1

9. Water booster( solar pump) x1

10. Flow sensor x1

11. Songle two- channel Switch Relay 250ACV 30A/ 30DCV 30A x1

12. Coupling/ reducer 1’ x3

13. Adaptor male 1’ x3

14. Adaptor female ½’ x2

15. Flexible water plumbing 1’ 3m x1

16. Foot valve 1’ x1

17. Teflon x1

18. PVC cement solvent x1

To get the size of wire simply as this, 1hp=746W since single Phase, we have to divide it to

230 then we have the result 3.24A. 3.24A is capable of 15A 2.0 mm2, However the minimum

size of wire of building lighting is 3.5mm2 and power load is 5.5mm2, if wire is over 100’ the

size of wire must be increased by one-step of size of wire [11].

3.2 Implementation
To implement this project, labor is recommended in order to assists us manpower and also

electricians done by a group, first in the shown below Figure 3.3, we have to install the

water booster before the centrifugal pump to get initial pleasure of water to insure the inlet

of pump is filled second, installation of suction plumbing very tight and foot valve to

prevent friction or cavitations. Finally, an automated system to run a centrifugal pump after

sensing the flow sensor. This type of method is to insure free hand pumps and also the

purpose of this project.

Figure 3.3 Installation of the Water booster

3.3 Testing

Arduino Uno Microcontroller is an open source hardware software platform that builds on

the Atmel AR and ARM microcontroller due to its widely used application C++ language is

similar to this algorithm[12]. The process of testing as follows;

1. Check the switch relay using arduino uno, if the bulb is lit on-off or small appliances

will run.

2. Check the water booster using arduino uno, if the portable water booster on-off

3. Check the water flow sensor using arduino uno, and then analyze the output/result

then construct the formula to perform the base of our automation

4. Test the small build construct such as bulb, water booster, flow sensor, arduino uno.

Noted that bulb as a 230 volts motor centrifugal pump.

5. Test the with centrifugal pump with bulb full test using another spare centrifugal

pump and use water tank instead of river

Chapter VI
Implementation and Testing

4.1 Software Testing

Software testing to make sure our algorithms or code what we used is verified, since

we use Arduino uno. Arduino uno is compatible language of C++ and easy to

troubleshooting if our program encounters some difficulty or faults, in this project we

shows how our program run as follows:

4.1.1 Songle 2-Channel Relay Software Testing

As you we can see the program what we use. We intended to do this simple program

just like we coding or the same algorithms of On-Off Led. To insure if our Songle 2-Channel

Relay is perfectly trigger. If not working, just check if your USB port connected to your

Arduino perfectly and makes sure your connection is correct as indicate the sign.

int ch_1=7; // declare channel as digital pin7

int ch_2=8; //declare channel as digital pin8

void setup() { // put your setup code here, to run once:

pinMode(ch_1,OUTPUT); //we tell to Arduino “Hey micro Processor that ch_1 is Output
pinMode(ch_2,OUTPUT); //we tell to Arduino “Hey micro Processor that ch_2 is Output
Serial.begin(9600); //this is important if we use serial monitor in arduino
}
void loop() {// put your main code here, to run repeatedly:
digitalWrite(ch_1,HIGH); //channel 1 trigger on. Meaning our relay is switch on
digitalWrite(ch_2,HIGH); // channel 2 trigger on. Meaning our relay is switch on
delay(5400000); //delaying to stay on within 1hr and 30mins
digitalWrite(ch_1,LOW); // channel 1 trigger off. Meaning our relay is switch off
digitalWrite(ch_2,LOW); // channel 2 trigger off. Meaning our relay is switch off
delay(5400000);} // delaying to stay on within 1hr and 30mins

4.1.2 Flow sensor software Testing

This flow sensor design for accurate calculation and detection of flow either air or water.

We used this as detection of flow of water, as we you see the program below as follows:
double delay_1=1000;
volatile int flowFreq; //Measure flow sensor pulses
unsigned int lHr; //calculated liter/hour
unsigned char flowSensor=2; //sensor input
unsigned long currentTime;
unsigned long cloopTime;
void flow( ) //Interrupt function
{
flowFreq++;
}
void setup( ) // put your setup code here, to run once:
{
pinMode(flowSensor,INPUT);
digitalWrite(flowSensor,HIGH); //Optional internal pull-up
Serial.begin(9600);
attachInterrupt(0,flow,RISING); //setup Interrupt
sei( ); //Enable interrupts
currentTime=millis( );
cloopTime=currentTime;
}
void loop( ) // put your main code here, to run repeatedly:
{
currentTime=millis( ); //Every second, calculate and print litres/hours
if(currentTime>=(cloopTime+1000))
{
cloopTime=currentTime;
lHr=(flowFreq*60/7.5);
flowFreq=0;
Serial.print(lHr,DEC);
Serial.println(" L/hour ");
}
}
This program is from the references to insure the flow sensor is calculated accurately.

4.1.3 Final Software Testing

This is the final software we tested last last week as follow:

int ch_1=7;
int ch_2=8;
double delay_1=1000;
volatile int flowFreq;
unsigned int lHr;
unsigned char flowSensor=2;
unsigned long currentTime;
unsigned long cloopTime;
void flow(){
flowFreq++;

void setup() {
// put your setup code here, to run once:
pinMode(ch_1,OUTPUT);
pinMode(ch_2,OUTPUT);
pinMode(flowSensor,INPUT);
digitalWrite(flowSensor,HIGH);
Serial.begin(9600);
attachInterrupt(0,flow,RISING);
sei();
currentTime=millis();
cloopTime=currentTime;

void loop() {
// put your main code here, to run repeatedly:
currentTime=millis();
if(currentTime>=(cloopTime+1000))
{
cloopTime=currentTime;
lHr=(flowFreq*60/7.5);
flowFreq=0;
Serial.print(lHr,DEC);
Serial.println(" L/hour ");
}
if(lHr==0||lHr<250)
{
digitalWrite(ch_1,HIGH);
digitalWrite(ch_2,LOW);
delay(delay_1);
}
else
{
digitalWrite(ch_1,LOW);
digitalWrite(ch_2,HIGH);
delay(delay_1);
}
}
The final testing software is simply combine the algorithms and add if else statement for

automation. Noted that the core of our programs is based on the detection of water flow

sensor.

4.2 Software with Load Testing

After the successful of program then connect easy the load as follows:

4.2.1 Songle 2-channel Relay with Load Testing

To test the hardware or this component as such songle relay 30A, we used

slightly load in order to insure the capable of songle relay in first, until such thing

we connected 1Hp water pump. The example as follows:

 Rice Cooker 400W

 Hand drill 400W

 Glinder 520W

 Wood planer 580W

 Car Vacuum Cleaner 800W

 Centrifugal pump 1Hp

 DC Motor 180W

These examples are the same circuit and program setting to test purpose

only to see how songle relay 30A really capable to runs or operate. The wiring

diagram as shown below in figure 4.1 simple circuit of switch relay.

Figure 4.1 Wiring diagram of Songle Relay with Load

 4.2.2 Flow sensor with Load(water/liquid) Testing

To test the flow sensor the program must be uploading properly in arduino

and use this wiring diagram provided by electro schematic as shown in figure

4.2 wiring diagram of flow sensor with load below [19]. The load either we used

air or water, if detected using serial monitor success, if not double check the

wiring and more important is program or coding is correct algorithms or not, the

common problem is in void setup sometimes we forgot to include the

Serial.begin(9600); without this, serial monitor cannot run.

Figure 4.2 Wiring Diagram of flow sensor with load

4.3 Full Testing

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[19] working-with-water-flow-sensors-arduino
https://www.electroschematics.com/working-with-water-flow-sensors-arduino/
[Last accessed: September 14, 2021]