TECHNICAL UNIVESITY OF MOMBASA

FACULTY OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

FINAL YEAR PROJECT REPORT SUBMITTED IN PARTIAL

FULFILMENT OF THE REQUIREMENTS FOR THE AWARD OF
DEGREE OF BACHELOR OF SCIENCE IN MECHANICAL
ENGINEERING

PROJECT TITLE;

TECHNICAL AND ECONOMICAL STUDY ON SOLAR POWERED

PUMPING SYSTEM ALONG RIVER SABAKI.

SUBMITTED BY;

FAHAD HUSSEIN– BSME/1521/2014

KARANJA KAGOTHO-BSME/009J/2014

PROJECT SUPERVISOR: PROF J.F KANYUA

SUBMITTED ON: APRIL 2019

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TABLE OF CONTENTS
PAGE

Declaration
Dedication
Acknowledgement
Abstract
Table of Contents
Chapter One
1.0Introduction
1.1 General Introduction
1.2 Introduction to Solar Powered Pumping Systems
1.3 Introduction to Sabaki River
1.4 Problem Statement
1.5 Objectives of the Study
1.5.1 General Objectives
1.5.2 Specific Objectives
Chapter Two
2.0 Methodology
2.1 General Introduction to Methodology
2.2Literature Review
2.2.1Literature Review on Solar Powered Pumping System
2.2.2 Literature Review on Sabaki River and Neighboring
communities and Water need/Usage
2.3Market Research on Solar Powered Pump Systems
2.4Legal Framework
2.5Technical Design on Solar Powered Pump Systems

2
2.6 Theoretical Analysis of the Performance of Solar Powered
Pump Systems
2.7 Cost Estimates for SPPS
2.7.1 Plant/Equipment Cost
2.7.2 Transport Costs
2.7.3 Installation Costs
2.7.4 Operational and Maintenance Costs
2.8 Cost-Benefit Analysis
2.9 Conclusion and Recommendation
Chapter Three
Literature Review
2.1 literature Review on Solar Powered Pumping System
2.2 Literature Review on Sabaki River and Neighboring
Communities and Water Needs/Usage

Chapter Four
4.0 Market Survey
4.1 Research Study

Chapter Five
5.0 Legal Framework
Chapter Six
6.0 Theoretical Analysis of the Performance of SPPS

6.1.0 System Layout and Design

6.1.1 Design Flow rate for the Pump

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6.2 Optimum Pump Design
6.3 Power Required
6.4 PV cells Sizing
6.5 Actual Design: General System Layout
6.5.1 Design and Considerations
6.5.2 Piping System
6.6 Operation and Control
6.6.0 Voltage and Current Regulation
Chapter Seven
7.0 Technical Design of Solar Powered Pumping System

Chapter Eight
8.0 Cost Estimates for SPPS
8.1 Capital Cost
8.3 Maintenance Costs
8.3.1 Labour Cost
Chapter 9
9.1 Conclusions and Recommendations
References
Appendices
ACRONYMS

A-Amperes

V-Voltage

TDH-Total Dynamic Head

MPPT- Maximum Power Point Tracking

PV-Photovoltaic

4
PVC-Polyvinylchloride

DC-Direct Current

AC-Alternating Current

BOS-Balance of System

LIST OF FIGURES

Fig 1. Map of Sabaki River and its tributaries (Kenya Geographical Map, 2007)

Fig. 2. CAD Schematic Layout of a Solar Powered Pumping System

Fig 3. PV solar cell, PV solar panel and PV panel array (Morales, 2010)

Fig 4. Global Solar Powered System Market Volume by Product, 2012-2022

(Reuters, 2017)

Fig 5. Malindi Solar Isolation obtained from PVsyst software

Fig. 6 Datasheet for DAYLIFF D3 Solar Pump (Dayliff, 2019)

Fig. 7 Graph of Pump Head against Flow Rate of DAYLIFF D3 Solar Pump
(Dayliff, 2019)

Fig 8 Datasheet for Various Solar Powered Pumps (Dayliff, 2019)

Fig. 9 aluminum ground mount systems (Davis and Shirtliff).

Fig.10 Float Switch

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6
DECLARATION

We hereby declare that;

 This project is our own original work and that all sources cited will have
been duly acknowledged.
 This work has not been previously submitted by anyone for a degree at
Technical University of Mombasa or any other institution.

Name: FAHAD HUSSEIN Reg No: BSME/1521/2014

Signature: Date:
Name: KARANJA KAGOTHO Reg No: BSME/009J/2014
Signature: Date:

SUPERVISOR CONFIRMATION:
This project has been submitted to the Department of Mechanical and Automotive
Engineering, Technical University of Mombasa, with my knowledge as the
supervisor.
Name: PROF J F KANYUA
Signature: Date:

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ACKNOWLEDGEMENT

We would like to thank the Almighty God for His resources in strength and
wisdom to reach this far. We would also like to extend my heartfelt gratitude to our
parents for their invaluable love and support throughout our campus life.

A special word of thanks goes to our supervisor, Prof. Kanyua for his vital
guidance, comments, suggestion and support. To you we say God Bless you.

Finally, but not the least, to all those who have helped us during the course of the
research in one-way or the other, we say thank you so much and will remain
grateful to you all.

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 DEDICATION

We would like to dedicate this project to our family members.

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 ABSTRACT

Area along Sabaki River in Kilifi County receives little and unpredictable rainfall.
The little rainfall cannot support water requirement in the area hence the need to
utilize water from River Sabaki. However, the river is far from homes making it
challenging to utilize the water from the river.

To provide a solution to this problem, we undertook a project study on technical

and economic use of Solar powered Pumping System along river Sabaki. Since the
area has no grid connected electricity but receives abundant solar radiation, use of
solar powered system would be applicable.

During the project undertaking, we designed a solar power pumping system which
comprised of 195 watts PV module, water requirement of 3m3 in a day, pump flow
rate of 0.544m3/h ,storage water tank capacity of 10m3.

The system layout on the area comprised of a community tap and a redistribution
point which would be suitable during progressive expansion of the project.

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1.0 INTRODUCTION

1.1General Introduction

Water pumping worldwide is generally dependent on conventional electricity or

diesel generated electricity. Solar water pumping minimizes the dependence on
diesel, gas or coal-based electricity. The use of diesel-based water pumping
systems requires not only expensive fuels, but also create noise and air
pollution. The overall upfront cost, operation and maintenance cost, and
replacement of a diesel pump are 2–4 times higher than a solar photovoltaic
(PV) pump (Chandel, Naik and Chandel, 2015). Solar pumping systems are
environment friendly and require low maintenance with no fuel cost. Keeping
in view the absence of grid electricity in rural and remote areas in most parts of
world, PV pumping is one of the most promising applications of solar energy.
The technology is similar to any other conventional water pumping system
except that the power source is solar energy. The flow rate of pumped water is
dependent on incident solar radiation and size of PV array. A properly designed
PV system results in significant long-term cost savings as compared to
conventional pumping systems. In addition, tanks can be used for water storage
in place of requirement of batteries for electricity storage. Water requirement is
largely dependent on rains and is adversely affected by the non-availability of
water during dry season. However, maximum solar radiation is available during
dry spell as such more water can be pumped to meet water requirements. The
study focuses on use of solar powered pumps technology, performance
evaluation, optimal sizing, economic and environmental aspects, and viability
of PV water pumping systems along river Sabaki. The main objective of the
study is to present current research status, and identify research gaps and
impediments in the widespread propagation of solar water pumping technology.

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 The strategy and policy issues for the promotion of PV water pumping are also
presented.

1.2 Introduction to Solar Pumping System

Solar pumping system mainly consist of PV modules, solar pumping

inverters/controllers and pumps. These components function as follows;

 Solar Module-generate electricity

 Solar pumping inverter/controller-convert solar energy, control and run
the pumping system by making full use of solar energy.
 Pump-raise water to a suitable level
 Other components include:
 Mounting Bracket to fix the solar panel
 Junction box which is a combination of DC fuse, DC circuit-
breaker and other components to protect the solar module
 Outdoor Cabinet-IP54, waterproof for outdoor installation

1.3 Introduction to Sabaki River

The Athi-Galana-Sabaki River is the second longest river in Kenya (after

Tana River). It has a total length of 390km and drains an area of 70,000km2
(Whitehead, 1960). The river rises at 1 42’S as Athi River and enters Indian Ocean
as the Galana River (Sabaki River).

The Athi River flows across the Kapote and Athi plains, through Athi River
town, then takes a northern direction where it is met by the Nairobi River. It also
joins with Mbagathi River which originates from Ngong hills. Near Thika the river
forms the Fourteen Falls and turns south-south-east under the wooded slopes of the

12
Yatta ridge, which shuts in its basin on the east. Apart from the numerous small
feeders of the upper river, almost the only tributary is the Tsavo River, from the
east side of Kilimanjaro, which enters at about 3° S. It then turns east, and in its
lower course is known as the Sabaki (or Galana) River, which traverses the sterile
quartz-land of the outer plateau. Flowing east, it enters the Indian Ocean in 3° 10′
S., 10 km north of Malindi town.

1.4 Problem Statement

Area along River Sabaki in Kilifi County does not receive continuous rainfall
across the year to sustain water needs by the neighboring community. In fact, for
nearly five months (from December to April) this area experiences dry spell.
However, there is more than sufficient water in River Sabaki that is underutilized
and flows to the ocean. To curb water shortages, an efficient solar powered pump
should be installed and solar energy harnessed to pump this water for use by the
community.

1.5 OBJECTIVES OF THE STUDY

1.5.1 Main Objective

The aim of the project is to design a Solar Powered Pumping System as a means of
availing water for use along River Sabaki in Kilifi County.

1.5.2 Specific objectives

i. To identify key factors that affect the design of a solar powered pumping
system along Sabaki River.
ii. To determine and design system specifications which comprises of the
pump, the PV modules, charge controllers and the amount of water required.

13
iii. Assess the cost of equipment and installation of the Solar Powered pumping
system.

14
Fig 1 Map of Sabaki River and its tributaries (Kenya Geographical Map, 2007)

15
 CHAPTER TWO

2.0 METHODOLOGY
2.1 General Introduction to Methodology
Methodology refers to an explanation of sequence in which the project work will
be carried out and presented in the project report. Each subtopic in the sequence of
methodology translates into chapters.

2.2 Literature Review

This describes the theoretical content that gives information on basic requirements
of solar powered pumping systems. It also describes working principle of various
parts of SPPS. It also describes River Sabaki as the source of water for our
projects and the various water needs by the neighboring community along the
target area.

2.3 Market Research on Solar Powered Pump Systems

Describes availability of market for project design in the target location. This
dictates the viability of the project.

2.4 Legal Framework

Describes various government policies, institutional and legislative framework that
addresses establishment of development programs that have an impact on
environment and the ecosystem along natural resources such as rivers and lakes
NEMA-Natural Environment Management Authority
WRMA-Water Resource Management Authority
EMCA-Environmental Management Coordination Act
MENR-Ministry of Environment and Natural Resources

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2.5Technical Design on Solar Powered Pump Systems
2.6 Theoretical Analysis on Solar Powered Pump Systems
This describes our own analysis of the design of SPPS that we intend to design.
2.7 Cost Estimates for SPPS
This chapter involve estimation of expenses incurred in setting up of the unit and
the approximations or the exact values made depending on the financial
considerations. They include;
 Plant/Equipment Cost
 Transport Cost
 Installation Costs
 Operation and Maintenance Costs
2.8 Financial Analysis
This is a description of cost benefits of the project.

2.9 Conclusion and Recommendation

This is the final topic of the project that depicts what we arrived at for the project.it
also gives information on what should be done to advance the project so as to
advance what we already did.

17
 CHAPTER TWO

2.0 LITERATURE REVIEW.

2.1 Literature Review on Solar Powered Pumping System

Due to the limited size of the solar cell it only delivers a limited amount of power
under fixed current voltage conditions that are not practical for most applications.
In order to use solar electricity for practical devices which require a particular
voltage and/or current for their operation, a number of solar cells have to be
connected together to form a solar module, also called a PV module. For large-
scale generation of solar electricity, solar panels are connected together into a PV
array. Although the solar panels are the heart of a PV system, many other
components are required for a working system, as said very briefly above.
Together, these components are called the balance of system (BOS). Which
components are required depends on whether the system is connected to the
electricity grid or whether it is designed as a stand-alone system. The most
important components belonging to the BOS are (refer to Fig. 2):

 A mounting structure in order to fix the modules and direct them

towards the sun. There are two ways to mount solar modules: either on a
fixed structure or on a tracking structure. Fixed mounts are less expensive
and tolerate higher wind loading but have to be carefully oriented so they
face true south (not magnetic south). A tracking array follows the sun
across the sky.
 Energy storage as a vital part of stand-alone systems, because it assures
that the system can deliver electricity during the night and in periods of bad
weather. Usually, batteries are used as energy storage units.

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 DC-DC converters in order to convert the module output, which will
have a variable voltage depending on the time of the day and weather
conditions, to a compatible output voltage that can be used as input for an
inverter in a grid- connected system.
 Inverters that are used in grid-connected systems to convert the DC
electricity originating from the PV modules into AC electricity that can be
fed into the electricity grid. Many inverters have a DC-DC converter
included to convert the variable voltage of the PV array to a constant
voltage that is the input for the actual DC-AC converter. Also stand-alone
systems may have an inverter that is connected to the batteries. The design
of such an inverter differs considerably from that for a grid-connected
system.
 Charge controllers that are used in stand-alone systems to control
charging and often also discharging of the battery. They prevent the
batteries from being overcharged and also from being discharged via the
PV array during night. High end charge controllers also contain DC-DC
converters together with a maximum power point tracker in order to make
the PV voltage and current independent from the battery voltage and
current.
 Cables that are used to connect the different components of the PV system
with each other and to the electrical load. It is important to choose cables of
sufficient thickness in order to minimize resistive losses.
 Pump DC water pumps in general use one-third to one-half the energy of
conventional AC (Alternating Current) pumps. DC pumps are classed as
either displacement or centrifugal, and can be either submersible or surface
types. Displacement pumps use diaphragms, vanes or pistons to seal water

19
 in a chamber and force it through a discharge outlet. Centrifugal pumps use
a spinning impeller that adds energy to the water and pushes into the
system, similar to a water wheel. Submersible pumps, placed down a well or
sump, are highly reliable because they are not exposed to freezing
temperatures, do not need special protection from the elements, and do not
require priming. Surface pumps, located at or near the water surface, are
used primarily for moving water through a pipeline. Some surface pumps
can develop high heads and are suitable for moving water long distances or
to high elevations.

Float switch a float switch turns a pump on and off when filling the storage water
tank. It’s similar to the float in a toilet tank but is wired to the pump controller.
Low water cut-off electrodes protect the pump from low water conditions in the
pond.

Fig 2. CAD Schematic Layout of a Solar Powered Pumping System

2.2 Principle of operation

The PV modules supply electricity to inverter

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 The inverter converts DC to AC to drive the pump according to intensity of
sunshine.

Advantages of solar pumping system

 Auto-operation, labor free.

 Suitable to all kinds of pumps, including 3-Phase and single-Phase AC
and DC pumps.
 Wide range of input voltage, suitable to different PV modules Modular
design, easy to maintain international advanced components, safe and
reliable.
 Solar and mains power hybrid, 24 hours operation, remote control and
monitor customized solutions.

2.3 Literature Review on Sabaki River and Neighboring Communities and

Water Needs/Usage

Sabaki River drains into the Indian Ocean at a basin area of 70,000km 2. Its waters
are usually of low saline level, though contains sediments and rock particles, it can
be filtered for use. The rivers flows on almost flat area hence does not require a
very high pumping mechanism to supply water to the neighboring community. The
community that live along the area of study are Mijikendas. Some of the families
practice small scale agriculture hence require water to water their crops during
non-rainy season. Expanding water supply is a key mitigation strategy for small
scale farmers (International Solar Energy Society, 2017). Additionally, water is
also required for both human and livestock drinking. Hence, solar water pumping
is a mature, reliable, economically attractive solution to water shortages for
irrigation, livestock and community water supply.

21
Appendix 1

Individual PV solar cells are the fundamental building blocks of the solar panel. In
general PV cells are smaller in size and produce about one watt power. An
individual solar cell produces a voltage of 0.5 to 0.6V. In order to get sufficient
output voltage, PV cells are connected in series to form a PV module. PV systems
are frequently functioned at multiples of 12 volts; modules are usually designed for
optimal operation in these systems. While PV cells are connected in series, the
output current remains the same but the output voltage will be the total summation
of all cells formed the module. Schematic diagram on how PV cells connect to
form module as well as modules to form array.

Fig 3. PV solar cell, PV solar panel and PV panel array (Morales, 2010)

22
 CHAPTER FOUR

3.0 Market Survey

Solar water pumping System is a mature, reliable, and economically attractive

solution for off grid irrigation, livestock water, and community water supply
(Kunen et al., 2015). With increasing reliance on water pumping for food
security needs, and limited access to other energy sources for community along
River Sabaki, there is growth in market for Solar Powered Pumping Systems.
Financial, managerial, technical, market access and education challenges exists.
Public-private partnership have adopt the system since it is cost effective,
increases reliability of SPPS and improve technology access through innovative
financial models. These models help accelerate SPPS along the target area and
Kenya at large.

3.1 Research Study

According to Reuters (2017), SPPS is expected to grow rapidly over the

years. This has been fueled by growing preference towards solar pumps than diesel
pumps and increase in demand for automated pump systems. Additionally, there is
less availability of diesel pump spare parts and high capital investment. SPPS are
adopted in areas where water is scarce, insufficient electricity supply and erratic
rainfall.

Based on product, demand for AC Submerged pumps is rapidly growing

since it function to pump water from wells and river sources. Along River Sabaki,
there is abundant solar energy with a huge tapping potential. The government also
offers support in terms of financial incentives hence promoting SPPS market
growth.

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 350

300

250

200

150

100

50

0
2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022

DC Surface Suction AC Submersible DC Submersible AC floating

Fig 4. Global Solar Powered System Market Volume by Product, 2012-2022

(Reuters, 2017)

24
 CHAPTER FIVE
4.0 LEGAL FRAMEWORK

4.1 NEMA-Natural Environment Management Authority

This is a body that promote the integration of environmental considerations into
development policies, plans, programs and projects, with a view to ensuring the
proper management and rational utilization of environmental resources, on
sustainable yield basis, for the improvement of quality of human life in Kenya

4.2 WRMA-Water Resource Management Authority

This is a body based in Machakos, Kenya that functions to provide historical
discharge observation and gauge height data for the sampling.

4.3 EMCA-Environmental Management Coordination Act

An Act of 2009 that was enacted to provide appropriate legal and institutional
framework for the management of the environmental and for matters connected
therewith and incidental thereto.

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 CHAPTER SIX

6.0 THEORETICAL ANALYSIS

The following parameters are used in the design of an economical Solar Powered
Pumping System;

 The site specific solar energy available

 Volume of water required at a specific time and that in the storage(storage
volume equal to a 3 day water requirement capacity is recommended due to
system maintenance and cloud days)
 The Total Dynamic Head (TDH) for the pump (the equivalent height that
water must be raised, taking frictional losses in the pipes into account)
 Quality and quantity of available water
 Piping Layout system

6.1 Water Requirement

Assuming a unit system intends to serve 100 homes each with an average water
requirement of 100 litres per day, that amounts to:
100homes X 100litres/home/day = 10000litres/day = 10m3 /day

6.2 Water Source

Our water source for this project is river Sabaki which flows constantly thought the
year. It has also a sufficient depth hence there is no need of creating a reservoir.

6.3 Water Storage

A tank can be used to store enough water during peak energy production to meet
water needs in the event of cloudy weather or maintenance issues with the power
system. Ideally, the tank should be sized to store at least a three-day water supply.
26
Multiple tanks may be required if a very large volume of water is to be stored The
area where the tank is to be placed must be stripped of all organic material, debris,
roots, and sharp objects, such as rocks. The ground should then be leveled. An
elevated platform or stand is required to provide adequate gravity induced pressure
for the water delivery system to operate. For this system an elevated platform of
concrete 1.5 meter height is chosen to provide the adequate gravity. Since the
water requirement is 10m3, 3 tanks of capacity 10m3 are selected.

6.4 Solar Isolation

Solar isolation values for Malindi are obtained from the PVsyst software as shown

Fig 5. Malindi Solar Isolation obtained from PVsyst software

For this case, the average of all twelve months is what I used since the values are
relatively close.

27
6.5 Pump sizing and selection

Pump performance depends variedly on how much water the pump is moving and
the pressure it is creating. Pump characteristics allow you to control the operation
of the pump. The primary relationship worth noting is the fact that, as the flow
increases, the fluid pressure decreases.

a) Flow rate of the liquid required to be pumped is determined by the amount

of water needed i.e. the demand obtained by

…………………………………….1
Where; Q is the daily water demand (liters/hour)

b) Total differential head (TDH) is determined by the flowrate required and the
system itself. It has two components, the static head across the pump (𝐻𝑠𝑡) and
the total head loss (𝐻L). It’s given by:

𝑇𝐷𝐻 = 𝐻𝑠𝑡 + 𝐻L……………………………………………………………….2

c) Static head difference which is the difference between the discharge static
head and the suction static head i.e.

Static head difference = discharge static head – suction static head

Where;

 Discharge static head = Discharge vessel gas pressure head + elevation

of discharge pipe outlet – elevation of pump center line

 Suction static head = Suction vessel gas pressure head + elevation of

suction vessel liquid surface – elevation of pump center line
28
d) Total head loss

The total energy losses in the entire pipeline system includes friction losses, H f ,
and minor losses, Hm, from bends, valves, meters, exit and entrance losses. The
friction losses are determined by: pipe (inside) diameter, length of the pipe, the
flow rate and the pipe’s roughness.

The head lost due to friction within the pipes can be determined using the
Hazen- Williams flow resistance formula for steady uniform flow (Lamont,
1981).

The Hazen-Williams equation:

It was developed for water flow in larger pipes (diameters > 5cm) within a
moderate range of water velocity (V <3m/s) Where Q is the flow rate, 𝑑h is the
hydraulic diameter, R is the hydraulic radius.

………………….3

…………………………………………………
………4

Hazen-Williams coefficient, C, which depends on surface roughness, is

determined using Reynold’s number.

For total loss to be determined, the following parameters need to be known:

 Length of the pipes

29
  Diameters of the pipes
 Number and types of fittings (valves, bends etc.)

e) The actual head gained by the fluid (generated by the pump), HP, Can be
determined using Bernoulli’s equation as follows:

Where 𝐻L (𝑝𝑢𝑚𝑝) is the head that is lost during the pumping operation.

……………………6

Where is the difference in water levels between the pump sump and the
header tank

g) The theoretical power gained by the fluid, 𝑃P, is given by:

𝑃P = 𝜌𝑔𝑄𝐻P…………………………………………………………… 8

This value differs from the actual power consumed by the motor driving the
pump due to mechanical losses in the bearings and seals, leakages and/or fluid
friction. The static head, Hst, which is the difference in water levels in the
pond/pump sump and header tank together with HL, are system characteristics
forming the equation:

…………………………………………………
….9

30
 This is the equation that manufacturers use to generate the pump system curve
as well as the pump curve from the equation:

………………………………………………………………………
……..10

The theoretical pump power, Pt (theoretical), is given as;

………………………………………………………………………
……..11

Pump efficiency is usually given by the manufacturer but can also be given by:

……….12

6.6 Photovoltaic array sizing:

The efficiency of the PV module relates to the area of active cells exposed to the
sunlight. Monocrystalline are the most efficient, converting approximately 15
percent of the sun’s energy to electricity, but they are also the most expensive of
the three. Photovoltaic modules have typical warranties of 20 to 25 years, with life
expectancies approaching 30 years. A factor of 1.25 times the pump wattage
requirements is often used to determine the preliminary size of the required array.
This accounts for the energy losses in the modules and controller.

31
 1) The total power and energy consumption of all the loads that need to be
supplied by the solar power system is given as:

𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 𝑝𝑒𝑎𝑘 𝑝𝑢𝑚𝑝 𝑝𝑜𝑤𝑒𝑟 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑚𝑒𝑛𝑡 × 𝑓𝑎𝑐𝑡𝑜𝑟

𝑐𝑎𝑡𝑒𝑟𝑖𝑛𝑔 𝑓𝑜𝑟 𝑙𝑜𝑠𝑠𝑒𝑠…………………………………………13

2) The size of the PV modules is determined by (Morales, T., & Busch, J.

2010).

6.7 Solar Charge Controller.

The solar charge controller is rated against Amperage and Voltage capacities. It is
selected to match the voltage of the PV array and batteries. The size collection is
based on the short circuit current of the PV array

𝑆𝑜𝑙𝑎𝑟 𝑐ℎ𝑎𝑟𝑔𝑒 𝑐𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑟 𝑟𝑎𝑡𝑖𝑛𝑔 = 𝑇𝑜𝑡𝑎𝑙 𝑠ℎ𝑜𝑟𝑡 𝑐𝑖𝑟𝑐𝑢𝑖𝑡 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑜𝑓 𝑃𝑉

𝑎𝑟𝑟𝑎𝑦 ×
1.3…………………………………………………………………………15

32
 CHAPTER SEVEN

7.0 TECHNICAL DESIGN

7.1 Storage Tank.

Since water requirement in 3 days is about 9m3 a 10m3 storage tank would be
sufficient for water storage.

Tank selected is a plastic cylindrical Roto tank with a capacity of 10,000L

(262mmx209mm).

7.2 Solar Peak Hours

Average solar peak hours for the day are calculated using values obtained in Fig. 3
as:

However, there exists a slight difference between the highest and lowest value
hence the need to have considerations in pump selection.

7.3 Design Flow Rate of the Pump

The pump’s design flow rate is based on equation 1

 Static Head Difference

33
Since the pump is submersible, the suction head is zero and the delivery head is
10metres

 Head Loss

The pipe material that was selected was PVC pipes which have considerably low
friction losses, making them a suitable choice for long pipes because lower friction
losses leads to a reduced pump size and subsequent energy consumption. (Davis &
Shirtliff, 2014 product manual, page 291)

Using Hazen-Williams equation, (equation 4) head loss, assuming the delivery of

the pump will use a bigger pipe diameter (pipe length =10m), generated is
tabulated below;

D (m) 𝝑 ( 𝒎/ 𝒔𝒆𝒄) HL(m)

0.025 0.049 24.6906214

0.032 0.030 7.4285134

0.04 0.019 2.5083391

0.05 0.012 0.8469750

0.063 0.008 0.2751172

0.075 0.005 0.1177873

0.09 0.004 0.048512

0.11 0.003 0.0182731

0.16 0.001 0.0029516

0.2 0.001 0.0009967

34
Table 4: head loss for different pipe diameters, length = 6m, Q = 0.544m3/hr.

 Pressure Head

For this case, the pressure head was assumed to be negligible since the delivery
point is a tank and pressure delivery is not necessary.

 Pipe Size Selection

The pipe diameter selected was 40mm/0.040m. The smaller diameters were
selected because for long pipes, the piping cost can be considerably more
expensive than the pumping installation and a pipe size smaller matched to a larger
sized pump can reduce the investment cost (Davis & Shirtliff 2014 product manual
page 289) but increases the running cost.

7.4 Total Dynamic Head for the Pump (TDH)

TDH= Vertical lift + Pressure head+ friction loss

Pump Selection

Total Differential Head = 12.51m

Pump Flow Rate=

The pump can be selected by comparing the design flow rate and TDH calculated.
From the above calculations, market research of different companies favors the
DAYLIFF D3 Solar Pump from Davis and Shirtliff Company (Dayliff, 2019)
which I selected. It has the following technical specifications:

35
7.5 Pump power

Theoretical pump power

Pump efficiency is given by;

Actual pump power required is 160W

7.6 PV Module Sizing and Selection

Minimum power needed to operate the pump =

A single PV panel of 195W is sufficient. Open circuit voltage of 43V and short
circuit current of 5.17A.

7.7 Selection of solar charge controller

The pump is supplied with a self-contained multifunction MPPT (Maximum Power

Point Tracking) controller that tracks the solar module's maximum power output
voltage which varies with module temperature and irradiation levels. This ensures

36
maximum current output, typically +25% higher than conventional module
controllers and a similar increase in daily water output. The controller also protects
from over and under voltage, over current and low water level (if electrodes are
fitted) and features various indicator lights that give the pump’s operating status.

Short circuit control rating=𝑇𝑜𝑡𝑎𝑙 𝑠ℎ𝑜𝑟𝑡 𝑐𝑖𝑟𝑐𝑢𝑖𝑡 𝑐𝑢𝑟𝑟𝑒𝑛𝑡 𝑜𝑓 𝑃𝑉 𝑎𝑟𝑟𝑎𝑦 × 1.25

=5.17×1.5=6.4625A

7.8 Reservoir Construction

A circular well is dug close to the river and a shallow tunnel dug to direct water
from the river into the well. Both the well and the shallow tunnel are reinforced
with cravats of diameters 1m and 0.4m to prevent them from collapsing. A siltation
point is left at the center of the shallow channel to allow settling of collected
sediments. A wire gauge is also fitted at the entry point of water from the river to
prevent large solid particles from entering into the reservoir.

7.9 Array mounting bracket and rack

The PV array needs to be mounted securely to a tilted rack that is fixed to the
ground. If the modules are fixed, the orientation of the tilt is to the south and
should be equal to the site latitude. A well designed solar support structure is of
paramount importance to the long term performance of any solar system. Both
rooftop and ground mounted solar arrays have to endure substantial forces
including not only the weight of the panels but high wind loads as well. Aluminum

37
structures are suitable for installation heights up to 3m.

Fig. 9 aluminum ground mount systems (Davis and Shirtliff).

7.10 Float switch

Paddle type float switch with weight and 3m PVC cable. The switch is suitable for
both high level and low level control according to the wiring connections.

38
Fig.10 Float Switch

APPENDIX 3

39
Fig. 6 Datasheet for DAYLIFF D3 Solar Pump (Dayliff, 2019)

Fig. 7 Graph of Pump Head against Flow Rate of DAYLIFF D3 Solar Pump
(Dayliff, 2019)

Fig 8 Datasheet for Various Solar Powered Pumps (Dayliff, 2019)

40
OPERATING CONDITIONS

Pumped Liquid thin, clean, chemically non-aggressive

liquids with a sand content of less than
0.1%

Liquid Temperature +40C

Minimum immersion depth 0.5m

Maximum immersion depth 20m

Ambient temperature -20C - +50C

Minimum borehole diameter 125mm

PUMP INFORMATION

Model D3SOLAR120H

Type Helical Rotor

Dimensions (mm) DN 3/4"

Motor rating (W) 120

Dimension(mm) D 820

Input Power Required (W) 160

Input Voltage (V) 24

Dimension(mm) C 76

Weight (kg) 12

41
42
PV MODULE DATA

Model YL 195

Rated Power(W) 195

Nominal Voltage 24

Peak Voltage (V) 35

Open Circuit Voltage(V) 43

Short circuit Current(A) 5.17

Number of cells 72

Weight (kg) 14

CHAPTER EIGHT

8.0 Cost Estimates of SPPS

Cost analysis is carried out to analyze the feasibility of SPP. These costs include
the capital cost and the future costs, which include the operating cost, maintenance
cost and the replacement cost. The calculations are carried without considering the
government subsidy and other benefits of solar power installations.

8.1 Capital Cost.

The capital cost occurs once at the beginning of the project. It comprises the cost
of the equipment and accessories, the cost of the installation and the cost of
transport.

8.2 Maintenance cost

43
There are maintenance and replacement of the pumping systems applicable. The
maintenance schedule and details are dependent on the technology employed. The
service interval depends on the pump system used, water quality and depth of
installation. The replacement costs for the motor, pump and controller are
equivalent to the initial purchase cost. An overhaul includes the tasks of a minor
and major service, replacements of parts and requires skilled personnel.

8.3 Labor Cost.

Labor cost is evaluated using total working hours according to the time needed for
the project.

Item DESCRIPTION UNITS RATE COST(ksh)

2 Aluminum Ground 1 36000 36000

Mount Systems

3 Dayliff 195W 1 12700 12700

Multicrystalline Solar
Module 24VDC

4 DAYLIFF D3 Solar 1 100900 100900

Pump + Controller

7 wiring 10m 150 1500

44
8 PVC pipe D40 100 48 4800

9 Installation of SPPS 1 10000 10000

10 Well 1 1000 1000

11 10m3 Storage tank 1 98,650 98,650 (VAT

Inclusive)

12 Float switch 2 1000 2000

13 Binding wire 1 500 500

14 Steel bars 20m 500 10000

14 Cement 4 650 2600

16 Ballast 1 lorry 5000 5000

17 Sand 1 lorry 5000 5000

18 Wood 1’’x3’’ 20m 200 4000

19 Elbow joints pipe 3 150 450

TOTAL 295100

45
 CHAPTER NINE

CONCLUSION AND RECOMMENDATION

Conclusion

The crucial objective of this study was to design a solar powered pumping system
along Sabaki River. This was met after identification of key factors that affect the
design of solar powered pumping system such as solar insolation, the
determination and design of system specifications which comprised of the pump,
the PV modules, and the charge controllers.

The obtained climatic data on the site as well the pumping requirements of the
available solar pumps in the market reveal that solar power as an alternative source
of energy, is a viable solution for the water abstraction problems along Sabaki
River.

The solution offered was that of a D3SOLAR120H, 24V pump powered by a

195W solar panel operating during the day. The overhead tank which will be fitted
7m above the ground level will have a storage capacity of 10000L.

It is expected that once this project is adopted and implemented, it will be able to
provide a continuous supply of water for use by the community along River Sabaki
as well as relief them the burden of fetching water from the river and the risk of
hippopotamus.

Recommendations

The pump should be specifically designed for solar power. It is strongly

recommended to purchase the pump controller from the same manufacturer as the
pump. Using another manufacturer could cause several unforeseen problems and

46
even invalidate the pump’s warranty. If the pump does not contain a built-in check
valve, one should be installed to keep the water from flowing back into the well.
Very few pumps can handle reverse flow without reducing the life expectancy of
the pump. Pumps that are designed to drain during non-operation are meant for
extremely cold conditions to keep water from freezing in the lines. The pump
should be set no deeper than 2 feet above the bottom of the well to help prevent
heavy silt and sand from entering the pump’s intake and causing it to seize. The
storage tank should be sized to hold at least three days’ worth of water demand to
account for evenings and cloudy days. If the controller is not attached to the array
mounting bracket it can be placed in a secure shed or pump house, preferably water
tight and dust free. Periodic cleaning of the well to remove silt and other solid
sediments.

47
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