Human-powered waterpumps for small scale irrigation purposes in Zambia

Human-powered waterpumps for small scale irrigation

purposes in Zambia

Citation for published version (APA):

van Schijndel, J. J. (1990). Human-powered waterpumps for small scale irrigation purposes in Zambia: a survey

and a preliminary selection of pumps to be tested. Eindhoven University of Technology.

Document status and date:

Published: 01/01/1990

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Human-Dowered waterpumps for small scale

irrigation purposes in Zambia; a survey

and a preliminary selection of pumps

to be tested.

APPENDIX A: Information on pump 1-85.

J.J.

van Schijndel

February 1990

Eindhoven University of Technology

The Netherlands

..

.

PUMP SELECTION TABLES

The ratings in the following tables represent the "best judgment" of the

Project staff. They are based in large part on laboratory and/or field data,

which are summarized tor each pump in the Handpump Compendium

which follows Chapter 6.

PUMP SELECTION GUlDE 79

.,;,.- •• ,. ..... ~~.~'~~:>~ ..... -.~ .. T'"~ • ., ..... _ •

-, :,

...

-'~'

..

.;.~.-'.-~.~-~_ .... ---":"~" , .. ~-:

...

-..-.;:;...

..

,._., ...

-

.r ~~ . ...-...: . . ~ •. :...~ . . __ _ • __ .. • . ,"I. • _ _._ ... ' • ..:.. ... 4:.tJ .", t .:.. ) "e'

I

E:=:~iii.jj(.j"iiriili~!Bi,.j:'lJ:I.:g:;::;::::'-::'=::,=-1

waiting 10 be repaired. They thus take account ol the lact that

~

t

which are suitable lor village mainlenance and can be repaired q~

may be more ·reliable" than Ihose which require more CO~

maintenance, even if the latter break down less Irequently.

THE RATINGS

Ratings in !he

Pump

Selection Tab/es are based on evaluation of pump

performance in the laboratory and field trials. Three ratings are used:

00 Good

o

=

Adequate

- =

Does nat

meet minimum requirements

A more detailed interpretation of the ratings for specific headings

can

be found in !he eaner part of this Ctlapter.

lumn 1 -

Pump Name

The pumps

are

liste<! alphabetically in four sections. according 10 !he

ffia)(jmum pUrl'ping lift recomrnended by the manufacturer. The reference number which precedes eadh pump name indicates the order of the PlfllpS in !he Handpump Compendium.

lumn 2 -

Data

Souree

L The pump has been tested in the laboratory F The pump has trcId a minimum of 2 years' lield trials

(F) The pump has rad limited field trials

lumn 3 -

Discha

Rate

The disdlarge rate deemed 'adequate" for each pumping lift is noted at !he top of the appropriate taöle. The rate reduces as depth increases, lor the reasons explained r1 Box 5.1. Some deepwell pumps thus actIieve 1<lwer ratings for low-lift applications, where users wiU opt for pL;mps giving greater discharges. A special note is made where a pump is available wittl a range of co,'linder sizes or adjustable stroke length, to sul different depths.

lumn 4 -

Ease of lIaintenance

Ratings indicate !he

ease

with 'a!hich maintenance can be carried out by:

A A vi IIage caretakcef

B

An area mechanic C A mobrle mainter1ance team

lumn 5 -

Reliability

Re!iability rati1"9S

are

an indica1ion of !he proportion ol the time that the pvnp is !ikely to be functiOnlrIQ properly. Separate ratings are given lor di7'erent daily outputs. The ra:ings combine judgments ol the "mean time belore lailure" (MTBF) and !he probabie "downtime" when the pump is

olumn 6 -

Corrosion Resistance

Ratings are base<! primarily on the materials ol the downhole corl'Cl

nents. Galvanized steel pumprods and ri~ing mains are not corr~

resistant in aggressive water and eam a - rating.

olumn 7 -

Abrasion Resistance

Ratings indicate the pump's capability to pump sand-Iaden

w_

Performance in laboratory and field trials is combined with asse~ of the se al and valve types. For non-suction pumps, leather cupsea. are rated - • though the extent ol abrasion damage will be related: i !he daily output of the pump. Analysts may therefore accept lower TaIe: I pumps lor light duty appIications.

olumn 8 -

Manufacturing Needs

Ratings indicate the ease with which a pump could be manufactured

r

i

developing country with!he specilied level of industrial development. 1 Low induslTial base, limited quality control

2 Medium-level industry, no special processes

3 Advanced industry. good quality control

olumn 9 -

Short list

The Analyst develops a short list by entering a check mark agars'

those pumps meeting his selection criteria.

olumn 10 -

Ca

ifal Cost

Analysts should obtain current prices lor short-listed pumps.

olumn 11 -

Remarks

Special leatures ol individual pumps are noted in th is

cokP

I.

Amplification of the notes is given below ..

Amplification of the ratings

tor

individual pumps

can

be

tound in the Handpump Compendium

NOTES ON TABLES

Tf-e notes re/are to pumps

WIm

the same reference number - i.e. Nore 1.1 reters to PlJmp 14. /he Mi3Jidev. In the tab/es. ratings fo which the note re'ers are higr.ighted

LU

Note 1. The 00 corrosion rating lor the Abi-ASM is based on current mcdels. Earfier modeIs did suffer trom corrosion.

Note 2- The 0 corrosion ranmg for the Alridev is based on the use of staJnless steel pumprods, offerBd as an option.

Note 7. The Duba Tropie 7 s a high-discharge pump designed for !Wo-person operatien.

Notes 9 and 10. The India Mark " uses a gravity return on the p\Jnger. and requires a minimum cylinder setting ol 24 meters (one manufacrurer offers a fixed-link system for shallower settings).

80

Note 14. The Maldev is a pumphead only. All ratings are based

on

l'

use of conventional downhole components.

Note 16, Reliability ratings lor the Monolift are based on pumps

~

metal gears. Plastic gears were less reliable.

Note 21. The 00 corrosion rating lor the Vergnet is based on

oP"

modeis. Earlier models did suffer trom corrosion. 1"

Note 23, The 00 discharge rating lor the Volanta takes account

d ,

pump's adjustable stroke length. Present designs require a minimum diameter ol 11 Omm.

Note 30. Downhole components of the Kangaroo are corrosion

~

tant. The 0 rating relates to the pedal return spring. ~

Note 40. The Rower is designed as an irrigation pump, and haS a'

i Pump name

I

1. flGH UFT PUMPS (G-45 meters)

ahi.ASM L IFl

'5..-Mona~P3

L F

Is

Nlra AF84 L 'S I ; Deepset , Z)

SWti80

& 81

f

Vl1IQ.net Z3 Volan:a (F) F L F L

L F

-o

00

o

00'

o

00'

o'

o

o

o

o

00' 00' 00'

-o

o

00'

-o

00

IIT1:RMEDIATE LIFT PUMPS (0-25 meters)

I

~ l;O~nLD6

25 DMR(C

.

1

L F

F

L f

I

25 Nira AR6

I

Ll1N LIFT PUMPS (0-12 meters)

;:' Blair F ~...E1hiooia BP50 L ~ I{~~ rvu L F 11 Malaw: Mark V F ~ Nira .hF85 L F

I

.

.!

"!.ara

L F

i

1

~ON

PUMPS (0-7 meters)

~-AID Syction F ,1..I..~tnn L

i

.lnaJS;j

Suction

.E

i

!'

~

Suction

(~l

.I'

~w

No. 6 _l (F) ~ . Rn..u.... l IFl

~.

i~OO

~

:" &r\rv-_ •.•. ~ -"'11UNA1. PUMPS 00' 00' 00'

o

00 00 00 00 00 00 00 00 00 00 00 00 00 00 00

Maximum pumping lift -

7 meters

"Adequate" discharge rate -

19 liters/minute

I

- 00 00 00 0 1 - 00 ' 0 -00 0 0 0 0 00 00 0 o i o 0 - 00 00 00 0 1- - I - -- oo!oo 00 ! 0 1- 0 0 0 - - 100 0 0 0 0 0 - -- 00 00 00 0 - - ' -- 0 0 0 0 0 _ 0 _ - -- 00 00 00 .: 00. _0. - - -- 00 00 00 0 0 0 0 - 1 -- 00 00 00 0 0 0 0 - ' 0 -- 0 0 · 00 00 _00_ 0 - i - -- 1 0 0 00 00 00 0 0 0 . 0 -- 00 00 00 100 0 - - -- 0 0 0 0 0 0 0 0 0 -- - 0 - 00 00 00 '00 0

-

!

-

-- - 0 0 0 0 0 0 0 - 0 0 -- - 00 00 00'0 - i 00

--

oo

!

oo

00 '0 0 0 0 0 0 - = - 00 00 oo ! 0 1- - I - 0 - 00 00 00 00..QQ. 00 100

-o

00 00 00 00 0 00 0 -- 0 0 0 0 0 0 0 0

-o

00 00 00 00 00 00 00 0 o 0 00 00 00 00 00 00 - 00

o

00 - 00 o 00

o

00

o

00

o

00

o

00 00 00 00 00 ·0 00 - 00 - 0

o

00 00 00 00 00

o

0 - 0

o

00 - 0 0 0 0 0 0 0 0 0 0 0 0 - 0 0 0 - 0 0 0 0 0 0 0 - - - - 0 0 0 0 - 0 0 0 0 0 0 0 - - 0 - 0 0 0 0 00 00 00 00 0 - 00

o

0 00 00 0 0 0 0 0 00 0 0 0 - 0 00 00 0 0 0 0 0 00 0 - 00 - 0 0 0 0 0 - 00 00 00 0 1 - 0 00 - 0 00 0 0 0 0 0

o

- 1 - 00 00 00 00 00 00100 00

o

0 00 00 00 00 00 00 0 0 0 0 0 0 0

o

00 00 00 0 1- - 0 - 00 00 00 00 00 OOOO. Q . O 0 ·- DO DO

o

00 00 00 0 1- - - - 00 00

o

00 00 00 0 1 - 0 0 - 00 00

o

00 00

cY.I

2...1_ - 0 - .00 DO 00 00 00 00 0 1- - 00 - 00 00 DO DO 00 0 0 0 0 0 0 D DO 0 0 0 0

o

00 00 00 00 0 0 00 - 00 00

o

00 00 00 0 1- 0 - 00 00 Short Price list (US$) , !

i

Remarks See Note 1 See Note 2 See Note 7 See Note 9 See Note 10 See Note 14 See Note 16 See Note 21 See Note 23 7m max. lift

See

Note 30 '

i

7m max. lift I

i

I See Note40

~

1:(:

---+----+---+--+-~--~--~~_+--~--~_r--+_~----~--~---~

<1~---+--~---4--~+-4--+-+~-4--~+-~-+--~--~---~

~s

that discharge ratings are based on choice of the correct cylinder size trom a range offered by the manufacturer.

PUMP SELECTlON GUlDE 81

I

·

·

'-.'''''~ ..

'~.~.:r"'"(.~

'-'

.

'

"

~

:.

' ~~

:

;·k

_ . ___ .~ .... ""':"s....-_ . _._,

_

.

...

.

.

"

.. _

_

_...-..~

__

_ ...

.

...

'

..

'

..

;,IIii

..

...

'

·

'

M;

_iIiII.

\

IIiI

~

...

<~:

_

'

.

Cote d'lvoire/France

Ger'.eral DescriptIon

Th: !':!-ASM is a hybrid pump using a p..n::s::and manufactured in the Cote d·',c·~ and the hydraulically operated V~ pumping element made in France (P J""'O 21). There are na mechanical links

be':'JOS'S"l the above and below Qfound unr:s. "oIimary cylinder in the pumpstand is ::::o-rected by plastic hose to a stain-less ;;:~I casing, in which a flexible ru:ce"' ~embrane contracts and expands to -r:~"':Nater through a second hose to

~ ;.;..--"ce.

-oe

pumpstand is partly cast iron are ~"jy fabricated mild steel. Fulcrum

be:r-r;s are split and injection molded in n)'o- :rass or stainless steel is used for thë

-=rrary

drive cylinder and the brass pl.I'Ç': -as leather ring seals.

ManJtacture

T~ :J.J'"pstand is suitable for manufac-tu~ - ~eveloping countries with loundry, fa:rczoo and machining ski lis, and could be -o:i";ed for all-fabricated manufacture. Th~ :elow-ground pumping element re'J..;~ specialized techniques, high skill le.'?-s :rd high quality conlrol.

~

A:lca- 'nduslrie, 01 BP 343, Abidjan, 01 C:rE :'·'.oire.

lnó<::ative prices - Feb 1985

Per _ ,r

T wr

,:se

(per meIer)

98

US$690 US$3

Laboratorv Tests

Date tested: 1982 Reported: Han4Jumps Project Report No. 3

Performance

data

(typical values)

Head (meters) 7 25 45

Pumping rate (cydeslmin) 38 40 42

Volume/min (liters) 10 10 10 .

Input (watts) 82 129 175

MechanicaJ efficiency (%) 14 32 43

Maximum handle force (kg-I) 20 35 45

Footvalve leakage (mVmin) No significant leakage

The volume discharged per stroke ranged trom 0.25 liters

at

45 meters lift

to

0.27 liters at 7 meters lift.

Evalustion

The two test pumps were weil packed, but had suffered some damage. Threads on the pumphead base were damaged on one of the samples, and Ihe baseplates were distorted on both. Handle components were not correctly aligned on either pump.

Comprehensive and weil illustrated installation and maintenance Instruc-tions we re supplied in Freneh. Insta-lIation is straightforward and does not require lifting tackle. Lightweight poly-ethylene hoses connect the pumpstand with the pumping element.

Malntenance too is simpie.

Primary cylinder piston seals are likely to need frequent replaeement, but the task is straightforward and quick. The lightweight hoses mean th at the pumping element can be extracted by hand, without lifting tackle, and Ihe element itself is easy to dismantIe provided the appropriale hexa-gon keys are available. However, if the diaphragm fai/s, a full replacement unit is needed, at comparatively high cost.

The 4000 hour endurance test was carried out at 40 cycles per minute, with a simu/ated head of 45 meters, subsequently reduced to 20 meters. The original leather seals on the primary cyl-inder plunger ware out very early in the lest. They we re replaced with seals of different materials but conlinued to wear out rapidly. The fulcrum in the handle ware oul after about a third of Ihe test periad and the bolt securing the drive piston rad to the luierum broke at about the same lime. About half way through the endu-rance test, the rubber buffer in the plunger was lound to have collapsed and was replaced.

In contrast with Ihe problems experi

-eneed with the above ground components.

the below ground pumping element suff-ered na breakdowns and was stiJl in goad working order at the end of the 4000

hours.

Repeated lailure of the primary cyl-inder plunger seaJs was attribuled la sharp edges detected on the replenishing hole in the cylinder. The hole had not been properly deburred during manulacture - a difficult operation because of the position ofthe hole.

The manufacturer has changed the design ol the fulcrum and the pumprod fixing since the laboratory tests.

Corrosion was delected on the plunger rad and the pumping element end caps, and inside!he pumpstand.

Both the pumpstand and the handle were undamaged in Ihe Impact tests, and the pump completed the allotted 96,000 cycles of handle shock tests without failure.

Users quickly became accustomed to the rhythm required to operate the pump, but lound it tiring to use because of the comparatively low discharge rate and high efforts needed.

The overaJl conclusion ol the labor-alory trials was that there is a marked contrast between the reliability of the pumpstand and above ground works and that ol Ihe belowijround pumping element. While the pumping element proved very reliable, the pumpstand was judged to be unsuitable lor community water supply.

Madilications have since been made to the pumpstand. II the problems can be overcome, the Abi-ASM is seen as a potential VLOM pump because ol its simple installation and maintenanee requirements.

----_.-

--~-~ _.~.

-~-.---A4

Field Trials

Test conditions

Number Head Data of range available Country pumps (meters) (months)

Cote d'lvoire 8 10·30 13

The basic design concept ol the Abi--ASM pump has been to combine the positive leatures ol the Abi·MN and Verg net pumps. The Vergnet below-ground compo· nents are easy to install and extract and have good corrosion resistance. The lever operation ol the Ab; is generally prelerred to the loot-operated Vergnet by West Alrican users.

The ASM pump is still being

developed and improvements are needed in the pumpstand design (bearings, handle, piston/cylinder assembly). Imp-rovements are also being sought in the diaphragm, to bring greater reliability and Iower prices.

In Cote d'lvoire, the pump has proved easy to install. requiring no heavy equipment or special tools.

Maintenance too is quick and easy. The seals ol the primary cylinder plunger had to be replaced at intervals ol about six months and the plastic luierum bearings at a similarlrequency.

The diaphragm proved gene rally reliable, though when lailure did occur it was necessary to replace it, at a cost ol about US$ 200.

PUMP

The :J_~:l's discharge rate ranged

Irom 0.51: -:J cu m/h, which was judged

to be ade:;_~:e by most users. There is a

notabie ci~='ence between dlscharges

measured - !"le lield and these in the laboratory :'5Cnarge depends not only on

the numb€-' :i strokes per min_ne, but also

on the rh)-:-- applied. VIllagers operate the ASM a: 2':-35 strokes per minute at 50·

75% ol .~, stroke. The measured

discharge

s:es

at 10, 20. 30 and 40

strokes pe -,nute were respectively 3.2, 8.5, 15.8. ë.

-c

26 liters per mi~ute at lifts

between 1 Cr a'1d 20m.

No p":Ç,e'!1s were enro ... ntered with

corrosion. ë.-C the pump does not suffer

Irom abras,:r. However, sand. silt or clay

in the waw 00 enter the dléi;)'1ragm and

were resp::.-s,bie lor ruptures in several cases.

Users found the AS~fs pumping

action qun" acceptable, and !he pump has

high VLOM xtential.

Assessment

Ratings are based on bath

IaOoratory and field tests.

Discharge Rate

From the field trial results, Ihe pump is clearly capable of achieving reasonable discharges when used wth the right rhythm. It eams an 'adequate' (0) rating lor lifts of 12,

25 and 45 meters, but is below !he

mnimum lor a 7m lift.

Esse

of Maintenance

The above ground components ol

the Abi·ASM are easily maintained b,' village caretakers, but Ihe need

fcy skilled mechanics to dismantie

tt.e

pumping element means that

the pump is rated 'unsuitable- (-)

fcy Level A maintenance. Absence

0' rods and rising mains eams the

p_'mp a 'goocr (00) rating lor Level

B

maintenance at all pumping lifts.

Reliability

FJeld evidence ol breakdowns and repair interventions eams Ihe pump

a

00 rating

tor

reliability at a daily GJtput of 1.5 m3/d, 0 lor 4m3/d at 7, 12 and 25m ifts and - lor 8m3/d

aoo

lor 4m3/d at 45m.

Con'osion Resistance

Beiow ground components of the pump are made trom corrosion resistant materlals. Though some

corrosion

was

experienced with

ear1ier modeIs, and the pumpstand,

prWnary drive piston roef and

dlaphragm end caps are slightly

Vl#lerable te corrosion, !he pump

now eams a 00 rating.

Abrasion Resistance

The ASM pump is little affected by

abrasion,

as

!he pumping element

!las

no

seaJs. However, Ihe

diaphragm

can

rupture if sand or silt

fills Ihe element. The rating is thef'efore reduced to o.

Manufacturing Needs

"llis is a hybrid pump. The below

groond components require special

skiI!s,

but

!he pumpstand is

Slitable

tor

manufacture in

coontries with foundry, fabrication

and machining skilIs. Ratings lor

manufacturing environments 1,2

aoo

3

are

1herefore - , 0 and 0

respectively .

. .. ._ ... < •• 0#-~ • •• _.~ __ .... _ • .( ... _

Kenya

• I' i'; " I f ·

:

~

i

·

~.::

-"

;

,

'

f:

,r f' ·,,1·,'

.

'I,'~~ ~ ... . 1,"

General Description

The Alridev is a pump design developed during the course ol the Project with sup -port Irom donors, researdl organizations and private companies. Available in the public domain, the design has aimed 10 demonstrate !he VLOM concepts ol easy, low-cost maintenanc:e and suitatr ility lor manulacture in developing countries,

The present design. which began limited product ion in Kenya towards the end ol 1985, is being modified lurther as a result ol lield experiences. Production ol the pumphead has also started in smal! numbers in Malawi, as a second gene -ration ol its lorerunner the Maldev (Pump 14),

The Alridev pumpstand is an all-steel labrication consisting largely ol stock sections, and involves a minimum ol close -loleranee machining. The T-bar handle comes in !Wo versions: a 3:1 mechanical advantage lor 10-30 meters lift; and a 4.5:1 mechanical advantage lor 30-45m lift. A direct action version is under

100

'

.

. ... _ ~t,. __ .. de r' • tb _ . .. _ .

Laboratory Tests

THE AFRIDEV PUMP HAS NOT BEEN TESTED IN THE

CATR LABORATORY

development lor lower lifts. The different hand les mean that the same 50mm diameter long-stroke cylinder can be used lor all lifts (see Box 4.6 in Chapter 4). Handle bearings are twin bushes ol proprietary plastics which snap together.

Rising main is 63mm

00

solvent welded uPVC pipe susperded Irom the pumpstand using a compressed rubber cone. Standard pumprods are 10mm galvanized mild steel with sçecial hooked joints which eliminate threaos and need no tools lor assembly or dismantling. Stain-less steel pumprods are ava.lable at extra cost lor corrosive groundwater.

The standard 50mm cylinder is a long stainless steel tube sleeved into uPVC pipe. Plunger and lootvalve are identical components comprising !Wo plastic mol-dings permanently spin-we«Jed together (prototypes in !he lield were machined). A molded rubber valve bobbin snaps into the valve housing by hand. The plunger seal is also a snap lining, which

can

be installed by hand and removed with (he help ol a household knile. A lishing 1001. consisting

ol a sm all grappling device at !he end ol a length ol rope grips the lootvalve to remove it lor maintenance.

This lishing tooi and a lorged socket spanner are the only tools required lor installation and maintenance.

Manufacture

Though "modem" materials are used in !he

Alridev, all components can be locally manulactured in Kenya, with the excep-tion ol the stainless steel cylinder liners which are imported,

SupplIers

The Afridev design is available in !he

public domain. Inlonmation on individual manulacturers is available Irom The Regional Project Officer, Rural Water Supply Handpumps Project, The World Bank, PO Box

305n,

Nairobi. Kenya,

Indicative prlces - Targets

Complete pump to , 30 meters Spares pack US$450 US$12

PUMP

Field Trials

Test conditions

Number Head Data

of range availabie Country pumps (meters) (mon/hs)

Kenya 37 10-49

8

Malawi 3 10-25 12

As the Afridev design has developed,

different prototypes have been tested during field trials in Kenya and Malawi,

though the progressive nature of the design means that the monitoring time for newly developed components is neces-sarily restricted.

An important aspect of the design has been the extensive research and specialist advice on plastic components, particularly bearings.

Developments have concentrated on simplification of maintenance and meas-ures to maximize local manufacturing potential.

Installation is simpie; even at depths ol

45

meters, there is no need lor litting equipment. Two ski lied people can comp-lete installation in about two hours (mainly taken up in making the solvent-cement joints in the rising mains).

In Kenya, the Afridevs were installed on wells with pumping heads ol 10-50 meters, averaging 25-30 meters. These arduous test conditions led to very few breakdowns. Some early prototype plastic bearings seized due to poor dimensioning,

but since the present bearings were

installed at the beginning ol 1986, there has been linie wear, though corrosion ol bearing housings has resulted in some

darnage to the bearings.

Users like the Alridev. The varia.ble handle mechanica I advantage maintains a high discharge with easy operation over

a

range Irom 10 to 50 meters. Corrosion is nol a problem, il stainless steel roos

are

used when water is aggressive. Nrtrile rubber seals in the polished stainless steel cylinder lining give abrasion resis-tance, which is further improved by the

use

of a large diameter suction pipe. This minimizes sand ingress by reducing watel" veIocities at the cylinder intake.

The hooked connections on the

pumprods have proved successlul.

ena/)-~ng !Wo people to remove and replace

a

pi'Jnger and lootvalve Irom a depth ol 30m

in about30 minutes without the need lor kI-ting tackle or special tools. Some pumprod breakages have occurred, and these have been anributed to shortcomings in the

production of the hooked connections. The push-lit bearings also make village maintenance very easy.

Overall, the Alridev design is

now

demonstrating that deepwell handpumps

can

be maintained by villagers, effectively

and economically, and that locaJ

manufac-ture can produce reliable pumps at

an

atfordabIe cost.

CAUSES

or

ESSEN11AL INTERVENTlONS

2 2.5 -3 1.1

...

toe Z 2.5

..

IE :z Jo: % 0 _1..4

i

~ 0 0 2 0

i

1.2 0 I

~

L5

~

~o.a

u lil: j

'"'

_~

f;

EO .•

_:.

'"'

_~ :. 0..4 IE 0.5

:.

0.2 0 0

H[)..HanCSla RH-A.oc:I hanoer RM-Ihs.no ma.n PE~ng .I.menl

F-fulcrum PR-Pump '00 PS-Pdlon ...al F\I.sooc val we OT -Olher

PUMP

1j.

..

.

... 0...-" ...

Afridev

Assessment

Field testing has

beeft

carried out

on pre-production models ol the

Alridev. Design modif.cations are being made continoously, most recently

to

overcome problems identified with beamg housing corrosion and hooked pumprod manufacture. The ratings rellect field trial perfonmanoe so far, but

!he limited nature of these trials means that !he rati~ are not

weil substantiated at ths stage.

Discharge Rate

The variabIe handle mechanical

advantage ensures

a

high dis-charge lor

heads

frorr. 10 to SOm.

but the

"goocr

(00) r.tjng recluces ~ "adequate· (0)

ter

7m lifts,

where even !he shortest practical

handle could nat compete with

discharges from drect action pumps (a direct actio1 version of

!he Afridev is being deYeloped).

&se

of Maintenance

The Alridev is a

VLOM

pump, and

Nis have ronfirmed iIs easy maintenance. justifyflg !he 00 rating at all depths tor all

mainten-ance systerns.

Aeliability

The combination of ~ repairs and low frequency ol breakdowns

eams the pump a 00 rating lor

most

operating c:ordiOons,

redu-eng

to

0 tor iIts ol 4&n or a daily output 018m.Yd.

CofTosion Reslstance

All downhole

components

are

corrosion resistant

Ct

stainless steel pumprods

are

selected). However, comlSion of !he pump-head bearing housing reduces the rating too.

AbrasIon Resistance

The nitrile saai in 1he poIished stainless steel cylinder lining handles sand-laden water

reason-. ably weil, eaming Ihe pump

a

rating ol "adequate· (0

J

-Manu1acturing

Neects

The Afridev

uses a rumber

ol

modem materiaIs, !he majority ol which could be reliably processed in most developing OOi#ltries. The

need

to

in1)Ort staness steel cylinder linings and Ile quality control

needed

in plastics manu-tacture reduce !he 00 rating tor categories 2 and 3 ~ 0 tor

CategDfy 1 coontries.

Sr; Lanka

General Oescription

This is a deepwell version ol a pump derived Irom a basic design developed by !he Battelle Memoriallnstitute and Georgia InsliMe ol Technology on behall ol USAID. The pumpstand consists ol a cast iron drive head assembly and cast iron base joined by a steel tube. The lulcrum stand is pinned to !he pumps tand below

and the handle above, so that the lulcrum moves in an are as the handle is operated.

The cylinder is conventional but uses uPVC tube instead ol brass. The plunger is fitted wi!h two leather cupseals and there are !Wo !ootvaJves - one fitted to an extension pipe below Ihe cylinder.

Manufacture

Basic ski lis ~ loundry worl<., machining and leather crafting are needed to manu-lacture the pump and carelul quality control is needed to ensure interchange-ability ol

pé\rtS-Suppl/ers

The field test pumps were supplied by Diason Pumps Ltd, 112 Isipathana Mawatha, Cdombo 5, Sri Lanka.

The laboratory tests were carried out on pumps trom Honduras (the Funymaq)

and Indonesia (the Sumber Banyu).

Prlces -

Not available

The AID Defivative pumps are specilically designed to be manulactured in the deve-loping country in which they will be used.

Local prices should be obtained. -.",

• __ ., ... __ ... ". , "%2' .

@

Laboratory Tests

The AID Derivative manulactured in

sn

Lanka has not been tested in f'e CATR Laboratory. This evaluation is related to the tesling of pumps based on the sa;-e :1esign manulactured in Honduras (the Funymaq) and Indonesia (ttle Sumber B.ry1..i. The

pumps were tested in 1983/84 and separate reports are included in Handpurrps

?-::;eet

Report No. 3,

Performance data (typIcai values)

Head (meters)

7

25

~

Pump· SB FM

sa

FM

SB Rot

Pumping rate (cyclesImin) 40

38

30

29

30 30

Volume/min (liters) 34 27

2S

20 24

21

Input (watts)

67

85 145 134 229 ZlO

Mechanical efficiency (%) 58 35 69 61 76 66 Maximum handle lorce (kg-I) 10 12 30 30 45 50 Footvalve leakage (mVmin) NS

NS

0.4 NS 2.4

NS

• SB

=

Sumber Banyu;, 78mm cylinder; FM - Fooymaq, lOmm cylinder; !'iS:

No

significant leakage,

Evaluation

Though the basic design ol the !Wo pumps is the same, the Funymaq performed much better in the endurance tests than the Sumber Banyu. It would therelore be unwise to draw general conclusions about

all AID Derivatives on the basis ol these tests, though they do indicate pointers to be taken into consideration when evalu-ating the pumps.

For example, both pumps demand a substantial complement ol tools and equip-ment lor InstalIation and mainte-na nee and there was difficulty in assembling the pumps Irom the compo-nents supplied. In the case ol the Sumber Banyu, components ol the !Wo sample pumps were not interchangeable, and the spares supplied did not lit either pump. The Funymaq pump tops did not fit the bodies (holes were drilled in the wrong positions) and the handles were stift to operate. Clearly, good quality control is needed il pumps are to be serviceable.

The design is such that Irequent lubrication ol the handle and lulcrum link pivots is needed lor satislactory pump operation. Below ground maintenance inv-olves removal ol the complete assembly and therelore needs heavy lifting equip-ment, and Irequent attention is likely to be needed to the leather cupseals and loot-valves.

Initially, the 4000 hour enduranee test on the Sumber Banyu was conducted at 40 cycles per minute with a simulated head ol 45 meters. Rapid we ar ol linkages in the pumpstand, broken rods and worn lootvalves led to live lailures in

the IJst 1000 hours, and !re "Ie:ld was reduced to 30 meters lor !he ~arder of

the tests.

Pumprod lailures contin:.ec 1:) accur,

incluóng !Wo lailures ol !he ;:x.;-çer rad when the lootvalve leather -::Efj away and aJlowed ttle cast iron weg'"! 1:) 'out the

plurçer. At ttle end of !he :es"L

:ne

C)1-inder end caps were heavil, NSted, !he plurçer and cupseals ware ~It n good

concilion and the cylinder

xre

.-as

pol-ishec1 but o!herwise showin; ~* signs of we ar. All other parts had be:;r. -e:oaced at sor.-e stage.

The Funymaq was :=-S:~: at 30 meters simulated head tro,- ~ ;!3rt and

per'ormed very much ~ ~an the Sumber Banyu. Only one ~;L.

-e

xcurred dur'ng the 4000 hours, ~

:-e

leather 100000Iaive broke away and ;a,~ severe

da~age to !he plunger a-c

:-e

cylinder bore. There was considef3:1€ -o:>ar in the ha:-dle bearings and guidf x):<s by the er<! ol the 4000 hours. :"1:l...gh they renained serviceable. ~

=

..;-

.

•

-naq was baCly corroded at the end :f :-oe :est.

The Sumber Bany~ :2-=<e casting

b~e at 400 Joules in

:-e

impact test bI.-t Ihe heavier casling :f :->: FunyrT'aq sl.lVived without damage.

The overall ~ ol Ihe taooratory tests was thal

:-oe

:,JO design

~.as some shortcomings. r :r-::<:utar. the SèCond lootvaJve is rea_ "'C:I< and can actually cause worse oa-~ ::"an would occur without it. Good :;I...è:~.' controt is reeded if the pump IS ::: :l:? used lor community water suppl,

,,:x:

~IS was not achieved on the pumps le;;:ec

' .... :

. '- .

.;

I . ir ..

AID

Derivative (Deepwell)

Field Trials

Test conditions

Number Head Data

of range availablf

Country

pumps (meters) (monttl$

Sri Lanka 9 2.6°-5.2 11

° Average head

In the Sri Lankan field trials, the deepwel pumps operated at only small pumping 11'":5

and with comparatively low outpU1S. Tr-.e field trials therefore yield little evidence ;;f

the pump's likely performance in high Ir':

applications.

No instruC1ion manual was supplie: with the pumps. Skilled workers a-: needed tor installation and they must b:

equipped with tools and lifting equipme~

On average, it took four workers about toIo:

hours to instal! each pump. A concre.:

pedestal is desirabie, to lift the operator 1:)

a comfortabie position.

The exposed drive head means !hE:

frequent lubrication is needed of th:

pumphead moving parts (at least once

a

month). The whole pump assembly has 1:)

be removed for any repair to the plunger

er-valve assembly, and this means that

a

pump mechanic and !Wo trained worke:; must be available with special tools are ski 115. Great care is needed in handling th: cast iron parts. A new gas ket is neeOe:

each time that the pumpstand is removec. and care is needed when dismantling !hé

threaded cylinder cap from the uPVC cylinder.

All test pumps performed withoLf. major failure, but leather cupseals were replaced on three pumps. Plungers ant!

check valves remained in good condition and there were few signs of wear on the cylinders. Crosshead guides and blocks were wom but still serviceable and little wear occurred on the fulcrum and rodhanger pins, which were weil lubricated during the trials.

The pumping action and relatively high delivery (24 liters per minute at 30

strokes per minute) we re popular with the users, and the pumps proved weil suited to this comparativety light duty. It was clear however th at maintenance commit-ments will be quite high and call tor significant resources in terms of manpower and equipment.

Laboratory probIems over the interchangeability of components were not encountered in the field trials on Sri Lankan manufaC1ured pumps.

In concluding !hat the pump is adequate for very !ow lifts and relatively light use, it must be recognized that a suC1ion version of the pump (Pump No 34)

is available tor lifts up to 7 meters, and has the advantage !hat the cylinder does not have to be lifted

out

lor maintenance.

CAUSES OF'

ESSENTIA:..

INltRVEN110NS

10 0.' 0.04 I 0 0 0

J

0.3 0.2

•

E

~ O.t 2 L.. ... _ -... --.lllfl-Iii'l'....,.-_--'-O.O 0

~ndle RH-Roei h.lnoer RM-R .... nç ma" PE-Pumpmg elemenl F-Fuh:rum PR-Pump roei PS-Pisaon Ha FV-Foot v.lve OT -Other

PUMP

Assessment

Because all AID Deepwell field trial pumps were installed in shallow weiIs, 1tle laboratory tests have been especially important in rating this PUr1ll.

Dlacharge Rate

The pump delivers a high discharge lor moderate effort at shallow lifts, and eams a "goed"

(00) rating lor ifts of 7 and 12 meters. The high handle force needed at higher heads reduces the rating

to

"'adequate' (0) at 25 and 45 meters.

Ease of MaIntenance

The naed lor ifting gear and special tools means thal the pump is rated "Unsuitableo (-) for Level A maintenance. At 7m and

12m. area mechanics

can

readily carry out maintenance, eaming a

00 rating lor level B, but this

drops

to

0 al 2Sm and 45m, where lifting gear bealmes essentiaJ.

Rellabllity

Laboratory tesis showed !hat the

AID Deepwell pump would need excessive maintenance lor anything other !han low ift and Iow output applications.

h

is therefore rated - tor lifts higher than 12 meters and lor high

output appJications at all lifts

Corroslon Resistance

Heavy corrosion occurred in the Jaboratory tests and some rusting was apparent in the field trials. The rating is theretore - .

Abrasion ResisCance

Leather cupseals are known to be

a problem when sand is present in the water, and the pump is therefore raled - lor abrasion resistance.

Manufacturing Needs

A1though intended for manufacture in developing countries, the AID Deepwell needs carelul quality control of casting and machining. h

therelore rates lor manufacturing environment 1 (\ow

industrial deveIopment) , but 00

tor environments 2 and 3.

103

Zambia

I

---1

_{. .?'}

_{Laboratery Tests}

_I

Tt(' handJr

General Descriptien

The Bestobell is a conventional lever-action deepwel! force pump, designed and manufactured in Zambia. The pumpstand and T-shaped handle are fabricated from mild steel. Handle bearings are bali races. A single spanner fits all the fastenings in the pumpstand. The pump is designed to use uPVC rising main. With 2 inch rising main, the piston may be withdrawn without removing the main. Footvalve mainte-nance does require extraction of the full below ground assembly. Pumprods are 12mm steel with threaded connectors.

The cylinder is heavy duty uPVC pipe. Early models used leather ring seals, but the current design has a molded rubber seal fitted to the uPVC piston body. Piston components are also used in the footvalve, or aSocia valve is supplied as anoption.

.Manufacture

Above and below ground components are suitable for manufacture in many devel-oping countries, with care needed in alig-ning and assembling handle bearings and in cutting threads in the cylinder barrel.

Suppliers

BestobelI Zambia Ltd, 875 Zambia Road, PO Box 230003, Ndola, Zambia.

Indicative prices - 1986

Per unit, excluding pumprod and rising main

104

US$225

Date tested: t 986

Performance data

(typical

vaJues)

Head (meters)

Pu~ngra!e(cyc~rrUn)

Volume/min (liters) Input (watts)

Mechanical efficiency (%)

Maximum handle force (kg-f)

Footvalve leakage (mVmin)

Evaluatlon

The !wo test pumps were securely pad<ed

in a wooden case. Bearings in ene randle assembly were in poor condition. possibly as a result of damage during assembly. Otherwise, both pumps were recefved in goed condition.

Comprehensive and helpfuI instruc-tions were supplied in Engrlsr!. Insta!-lation is relatively easy, with no reed for

lifting tackle, provided that uPVC ~sing

maln is used (the pump can aIso be used

with galvanized steel rising maln).

Malntenance is also

straight-forward, as the plunger can be WI'ltO'awn

without removing the rising main (:hJugh

the who Ie below-ground assembly ~t be

removed to service the footva!ve. One spanner fits all the pumpstand tastenngs,

but care wil! be needed when new harldle

bearings have to be titted.

The 4000 hour endurance test

was carried out at 40 cycles per ~ute,

with a simulated head ot 45 meters. At the

beginning of the test, the pump was ~ned

with a piston of the early design. with leather ring seals. There we re no 'a;lures in the first 2000 hours. when PI-:-:-ping clean water. However, when the cyinder was dismantled tor inspection, the ;::oston

body was found to have broken ber .. een the !wo leather seals.

The piston was replaced. but 'ailed

soon after the start of the second p."ase of Ihe test, when sand and Kieselg\.JY had been added to the water. Sand err:becded in the leather seals had caused se<ere wear of the cylinder bore. The foor.aJve had also developed a serious leak. :gain

7 43 12 29 49 6

Reported: Report nat yet published

25

40 11

71

63

15 No significant leakage 45 40 11 111 71 26

due to sand contamination. A new piston, machined from uPVC and with a molded rubber seal, was fitted, along with aSocia

footvaive. In this form, the pump

completed the remainder of the endurance test. Both piston and footvalve ware in goed working order at the final inspectio,!.

Following these tests, the manufac-turer has adopted a piston design gjmilar to that introduced in the laboratory. and intends to usa the same components in the footvalve. The S.ocla valve will be avail-able as an altemative.

Corrosion was detected ins'ade the

pumpstand and on the center spindle of

the original piston, which was not stain-lesssteei.

In the Impact tests. the baseplate was distorted by a heavy impact on the pumpstand, and a small crack appeared at the weid. The handle fulcrum bracket broke during Ihe handle shock test.

The pump was generally weil rec-eived by users, who liked the T-handle and the relatively low efforts required. However, some adults considered that the rate of delivery was rather low.

The overall concluslon of the laboratory tests was that the Bestobell was a design with goed potential tor manufacture, maintenance and repa!r in developing countries, but requiring some additional development before it could be considered tor large scale application.

The manutacturer has been

hampered by the limited availability of suitable materials in Zambia, but nas nevertheless demonstrated a receptive and t1exible attitude.

PUMP

Field Trials

THE BESTOBELL PUMP HAS NOT BEEN TESTED IN

THE PROJECT FIELD TRIALS

PUMP

~ ... ~~ n . . . , II!".' IIIIII""",',""--'~-'~'

.

.

r .

BestobelI

Assessment

The

BestobeI1

ratings are based

on lts perlormance in Iaboratory

trials and on judgments of the

Project s1aff using oomparisons

with ptJITl)S of similar design.

Dlscharge Rate

Though!he pump is

easy

to usa,

it is difficult

to

sustlin

a

very high

output. Wrth acx:eptable WOrK

inputs, it scores en "adequate" (0) rating fOf all lifts.

Ease of Malntenance

Even at shallow settings, !he

pump is not suitable tor main·

tenance by a village caretaker

(Level A), though area mechanics

wil! tind it easy to service. Uiting

gear is likely

to

be neeóed for lifts

of 25 meters or more. The pump

therefOfe eams a "good" (00)

rating lOf Level B

mairaenance

at

7m and 12m, reducing to

"adequate" (0) at 25m éWld 45m.

Rellability

Replacement of the onpinal piston

with a

new

design ifTl)l'oved !he

pump's performance in the

laboratOf)' trials. In its new form,

reliabi Iity is rated as 00 for an

output

of 1.5m3/d, and 0 for 4m3/d

at lifts

up

to

25 meters.. h is not

considered suitable

tor

a daily

output of &n3/d and wiCh presently

available data, it is c:onsidered

prudent te rate ft "unsultable" (-) for 4m3/d at a 11ft of 45m.

Corrosion

Reslstanc:e

Wrth stainIess steef

pumprods,

and piston spindIe, no corrosion

of downhole c:omponents

occurred in the IaborëIIDry trials.

Spots of rust inside the

pumpstand reduce the rating to o.

Abrasion Aeslstance

After replacement of h \eather

saais with molded rubber, a üttIe

abrasion occurred in the

laboratOf)' tests, but 1he pump

remained in good wortórlg order. h

!herefare eams a 0 rating.

Manufactur1ng

Needs

Though !he Bestobel has been

designed lor manufacture in a

developing country, a degree of

quality c:ontrol

is

needect This

reduces

Ihs

00 rating

to

0 for

manufaaumg envirorment 1 (Iow

level of

inclJstrial

deveIopment).

..

... " _~~ .... ilIoo,....l,&._. _ _ ~, .!.,.~_ •.

®

United Kingdom

.,'

"

i~

l

+

~CIl

~

.

11'

\

~/

General Description

The Climax is a rotary~rive reciprocating

force pump of long-standing design. The

pumpstand is predominantly cast iron and

has a large counterbalanced flywheel

driving the pumprod via a crank and

conn-ecting rod. Twin flywheels are available

as

an option. Internal medlanical parts are

splash lubricated Irom an oil bath. A

moving pumprod seal in a cylinder below

the crank provides a double-acting effect

to smooth the Ilowol water.

A range of cylinder diameters is

avail-able to suit different depths. The cylinder

is a brass tube with a gunmetal plunger

fitted with !wo leather seals. An alternative model is available with extraetabie pistoo

and lootvalve. Woeden pumprods are

supplied with the extraetabie vaJve

cylirder and galvanized steel rods with !he

non-extractable cylinder.

Manufacture

Bath pumpstand and cylinder require goOO iron and gunmetal loundry and machinery slolls with high quality cor.trol.

Suppliers

Wildon Engineering (Worcester) Ltd,

White-ladies Close. Little Loodon, Worcester.

WRllPZ.UK.

Indicative prices - Jul 1985

Single flywheel pump

50mm rising main (per meter) Pumprods and connectOf'S (m) Non-ex1ractable cylinder Extractable cylinder

106

US$480 US$7.50 US$3.10 US$90 US$105

Laboratory Tests

Date tested: 1979 Repot1ed: O.D.A Repo/11981

Perfonnance

data

(typIcaI values) -

2.25 Inch cylinder

Head (meters)

7

25

45

Pumping rats (cycJesImin) 29 60 29 60 29 60

Volume/min (liters) 9.3

19

9

18.5

8..7

18

Input (watts) 31 64 63

130

89

183

Mechanica!

efficiency ~ 33 32 58 58 73 73

Maximum handle force (110-1) 15 25

18

20 10

15

Footvalve Ieakage (mllnin) Not significant

0.8

3.5

Note:

The

maximum handle force is vel)' operator dependent

and

is

higher when starting

trom

rest

Evaluatlon

A

very

heavy pump (185 lig in all lor the pumpstand), which though complicated is

designed to have a longife. lts weight

means that InstallatIon and

malnte-nsnee involve the use r:J heavy lifting

equipment. Though the cotional

ex1rac-table cylinder avoids the "eed for rising

main removal during mantenance, the

pumpstand still has to be removed belore

the piston and vaJve can be ex1racted. The crank case oil needs periodic replen-ishment.

The design ol the pump proved

popular with most users. Use ol a very

heavy flywheel makes the pump smooth

and easy to operate. even :Jn deep wells,

though the starting and S?:lpping handle

load can be as high as 351g-l. Also, the

continuing flywheel rotation after the user

has stopped pumping is a 1azard to any

children who may stray near to the last

moving handle. The purrcstand design

makes it difficuit to achieve a satislactory

sanitary seal. as it is rela::Jvely easy lor

contaminated water to seep under the

base and down inside the wel casing. There are many exte-1al fixings on the pump, mainly nuts anc balts without

locking was hers. which are easy to

re move. The pump is not :-erelore resis-tant to vandalism or pilferage_

Leathers supplied w~ the sample

pumps were too thick (5rm instead ol

4.2mm). When the pump was installed the

operation was just satislac::ry, but after a lew days the leathers swelled and jammed

in the cylinder ..

Second and third SE":S ol leathers

purchased Irom the man~'acturer

expe-rienced the same probie,. so leathers lrom a different sou ree W€fe substituted and used in all the lests. These were

satislactQ('f, and mechanical efficiencies up to 74% were recorded.

The endurance

test

was

conducted at 40 cycles per minute with a

simulaled head ol 45 meters. The Climax

proved

very

reliable. There Wefe no

break-downs during the 4000 hoors ol pumping and no significant wear of key compo-nents. Some leakage through the

pump-stand inspection cover was easily rectified

and did not recur.

The high handle loads during starting and stopping did cause fatigue failure ol the handle at the threaded connection with the Ilywheel, where maximum bending Ioad

occurs. Repeat tests on a fatigue testing

machine revealed that loods as low as 20kg-1 could cause lailure within a million revolutions.

Use ol a brass cylinder with

galva-nized rising main and pumprods causes

corrosion problems in acidic waters, and

severa pitting occurred in bath the pipe and !he red near the cylinder when pum-ping water with a high dissolved oxygen content. Tha pumpstand withstood !he

Impact

tests

satisfactorily.

In comparison with other deepwell

pumps, the Climax's performance was

liked by users. The flywheel action gives

an even discharge Irom !he spout. and

most buckets could be filled without

splashing, though the relatively low spout

(375mm) may mean that some containers would have to be tilted.

The ov8f'8l1 conclusIon ol t11e

laboratory trials

was

that !he Climax is a

weil-made. easy to usa and reliable pump, liked by users. but with some minor problems with the handle and leathers

needing 10 be overcome. lts heavy

construction makes it unsuitable lor village-Ievei maimenance.

\ , ',

.

....

.

Field Trials

.

PUMP

~

~;

~

.

7-._

THE CLIMAX PUMP WAS NOT FIELD TESTED

BY THE HANDPUMPS PROJECT

..

.

Climax

Assessment

In

!he absence of field trials. ratings lor the Climax pump are base<:! mainly on performance in !he Iaboratory tests.

Discharge Rate

A range ol cylinders losuit different lifts allows the Climax to achieve

"goocr

(00) ratings tor all pumping lifts.

EMe of Malntenance

The pump is difficult to service and requires a mobile

mainte-nance

team tor installations at all

depths. It is therefore ratad unsuitable (-) lor maintenance

systems

A

and

B

.

Aeliabll ity

The pump per10rmed relatively weil in the laboratory endurance test and achieves a 00 rating lor reliability lor depths up to 25 meters and daily outputs up to

4m3Jd. The rating reduces to 0 lor

~ output of 8m3_{/d at all lifts and}

tor 4fn3/d at 45rn lift, where the

operating eftort and wear ot

moving parts

is

greater.

CorrosIon Reslstance

Corrosien OCQJrred in the Iaboratory, and the Climax's downhole components are not corrosion resistant. It is therelore rated unsuitable under this heading.

Abrasien Reslstance

The pump survived without breakdown in the Iaboratory

sand-pumping tests, but use ot !eather Q4)SeaJs means

a -

rating

tor

abrasion resistance.

llanufacturing Needs

The manufacturing lacilities and stalIs required

te

make the

Climax. and the degree ot quality cantroI needed. mean that it is unsuitable lor manufacture in

countries with

!ow

or moderate industriaI development (cate-gories 1 and 2). However, as specialist facilities are not ~red,

the

PUIJl) is rated 00 lor manufaclure under Category 3 (high level industrial deve-Iopment).

Japan

u

_l-

~

General Description

The Dragon pump is available either as a shallow·well suction pump or as a deepwell lorce pump. The pump tested was the deepwell conliguration, as illustrated. The pumpstand is principally cast iron. with a discharge valve in the spout allowing either tree discharge or delivery under pressure through a ho se or pipet The tubular steel handle moves through an unusually wide arc (178°).

In the deepwell pump. !he cast iron cylinder body and enamelled steel liner ol the shallow·well version is retained as a pedestal. The pump needs a mounting plinth at least 300mm high, to provide ade· quate clearance under the spout. The deepwell cylinder is conventional seam· less 63mm brass tube with cast iron end caps. The plunger has !Wo leather cup-seals and the lootvalve has a rubber seat.

Manufacture

Gunmetal and iron loundry work and basic machining are required and good quality contral is needed to ensure correct lunc-tioning and interchangeability ot parts.

Suppliers

Kawamoto Pump Manulacturing Co. 11 ·39

4-chome, Ohsu. Naka·ku, Nagoya.

Japan. Similar pumps made in the Philip-pines by Sea Commercial Inc (Jetmatic) and Malanday Machining and Manulac-turing Corp (Sea Horse).

Prices -

Not available

108

-....".--

;"'y,~.

"~ ___ ._..: .. ~_ .. __ . _ .. '-' ... " ... , ... • .. _ili~_'M ... t."tIli6 ... SIio'iiïi-**IIII"~ . . . '

Laboratory Tests

Date tested: 1982 Reported: Handpumps Pro,ect REport No. 3

Performance data (typlcal values) -

63mm dia. cylinder

Head (meters) 7

Pumping arc'

P

po

Pumping rate (cycles/min) 40 40

Volume/min (liters) 22 11

Input (watts) 80 35

Mechanica! effICiency (%) 31 34

Maximum handle force (kg-f) 8 8

Foot valve leakage (mVmin)

25

F 40 22 168

52

18 No signifICant leakage

45

F 40 21 244 63 30

• At 7 meters head, tests were conduct9d boiIJ with the tuil 1780 _t~1e move-ment (F

=

Full) and with on/y the centra/Waf movement utilized (P = PaltiaJ).

Eva/uatlon

The !Wo sample pumps we re weil packed and were received in good condition.

No InstalIation instructlons

were supplied with the pumps and installation proved difficult, as the cyl-inder stroke length is virtually the same as the handle movement in the pumphead and carelul adjustment ol pumprod length is needed to avoid damage during operation. A plinth is needed to provide adequate clearance under the pump spout. Lilting tackle is required tor pump installation.

Malntenance demands are likely 10

be high, involving regular lubrication and

frequent repair or replacement ol

pumpstand components. Below ground maintenance involves removal ol the complete assembly. which means that litting tackle must be available.

The 4000 hour endurance test was carried out at 40 strokes per minute with a simulated head ol 45 meters. The Dragon 2 tailed three times during the testing: once when the handle lork broke after wear had caused it to come in contact with the luierum pin relaining screw; and !Wice as a result of breaks in Ihe threaded section ol pumprods.

Alter 1000 hours, the plunger had become difficult to remove because of scale in the cylinder bare; the lootvalve guide and pumprod gland we re wom; the spout would not swivel into the pressure delivery position; and there was some corrosion ol cylinder end caps and the plunger rod. Inspeetion alter a lurther

1000 hoors revealed thar hande fulcrum

joints were badly wom and &ere were

signs of wear on the plunger valve. The three breakdowns occurred in the second half ol the :ests" The linaJ inspection revealed thaI :ne p..npstand.

cylirder and plunger ~e g€rerally in

goed condition. but the 'ootva'/e guide

was badly worn and thereNas s::me wear

on !he valve stem. The CIlinder :nd caps

were rusty, there was cO:'Slderable

corTOSion on the plunger rod. and the outJa diverter valve had n..:sted soid.

The Dragon 2 lailed :he SI:.:! impact test on the handle. whicn bega') to bend at !he Iowest impact enE"gy (5: Joules). AI 200 Joules. Ihe base casll-g ol Ihe purrç:lStand broke.

Many users 10unCl It dficult to deelde on the best o::eralirg action. beea.:Jse of the very large handle

movoement. Those who ~:tem~ a lull

slroke lound Ihe exa;;gera!:d body

movemenlS uncomlortable~

The overall condusion ol Ihe

la.bcr"atory lrials was Iha: Ihe : ragon 2 seens designed lor tamy use perhaps ser.·rng up to 15 people. and :s ~ot

suffi-ciertty robusl lor co-mun-:-! water

sup~. It is inexpensive. but nlensive use Nill produce rapid wear in

r:-.:

moving

parts ol the pumps~"d. :nd rod

brea<ages are also likey. Th,: diverter valve is seen as an unne:essa"! compli-catioo lor most applicallcns. T-e arc ol movoement is 100 large. partl::..:arly as Ihere is litlle pisIon mOI,:men: al each

end ol Ihe handle moveme-t.

Field Trials

PUMP,

THE DRAGON 2 PUMP WAS NOT FIELD TESTED

BY

THE HANDPUMPS PROJECT

.O:~"'I'j,~ ... _ . .. "" ... + _ _ ... "" .... _ ... __ :-.

-).\

Dragon 2

Assessment

In !he absence of field Inê!is

ratings for the Dragon 2 pump

ar:

based mainly on pertormarlC€ ir

!he laboratory tests. A sucror

version of the pump is availa:lo~

for lifts up to 7 meters. but thE:sE

ratings are based on the deePl"'='

version tested in !he Iaboralory.

Dlscharge

Rate

The Dragon 2 should be ca~E

of comparatively high lischa~

over the full range of pumprç

lifts. However, !he awkward

DPE-rating action reduces the ratinç 11:

"adequate" (0) in eacll tabIe. Eaae of Malntenance

Though lifting tackle is rr:r:

needed for shallow lifts (7 or 1;'

meters), the relative complei"

of servicing makes it unsuitiOe

forvillage-ievel maintenance

(Sto;-tem A) even

at

these lifts. ArëE.

mechanics would need asss

-tance for servicing at depths ~

25 meters or more so that

r.E

ratings for level B maintenarx:e

are "good" (00)

tor

lifts of 7m

a-c

12m and '~e" (0) for lifts ~

25mand45m_

Rellability

The laboratory

tests

showed

r.:::

the Dragon Is not weil suited I:

intensive use,

or

to pumping Itl:

of 25 meters or more. For Iow It.l:

and light use. servicing

nee::s

would not be higtI and \he pUfTlllS

!herefore rated 00 at ifts of 7rr

and 1201 lor a daily

output

~

1.5m3/d, 0 at fle same lifts b

4m3/d and - tor arnJid At 25r.

and 45m, !he

raMg

is-_

Corroslon

Reslstance

Significant conusion

was

obse!'-ved in the Iaboratory lests, é!r1C

!he Dragon is nol suitable for use

with cotTOSive water.

Abrasion Ru' .... ce

Use of leather aJPS6aJs earns l1e

pump a - rating lor abrasi7'

resistance .

. ManufacturIng Needs

The

Dragon 2

is not sUtabIe b

manufaclure in c:ountries with a

!ow level of industrial

develap-ment (category 1) because of lt1e

need lor foundry and machinf'ç

ski lis. For categories 2 iWld 3. ~

ratings

are

0 and 00 respectively.