hydraulic ram pump system design manual - us peace corps, philippines

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Brief Description of Content: The Hydraulic Ram Pump is a mechanical device that can pump water above the water source WITHOUT THE NEED FOR ELECTRICITY. This pump has many applications, especially in the rural, upland areas of the Philippines where water is difficult to access due to the need for electric pumping and the distance and expense of an electrical power source. This manual is intended to provide a comprehensive guide for site selection and Hydraulic Ram Pump system design.

Hydraulic Ram Pump System Design Manual Page Weil, EIT

US Peace Corps, Philippines (2006-2009)

INTRODUCTION .................................................................................................................................................................................. 1 1. THE BASICS................................................................................................................................................................................. 2

1.1. WHAT IS A HYDRAULIC RAM PUMP?...................................................................................................................................... 2 1.2. BASIC TERMS ........................................................................................................................................................................ 2 1.3. HOW DOES A RAM PUMP WORK? ........................................................................................................................................ 4 1.4. SYSTEM DESIGN PROCESS..................................................................................................................................................... 7

2. SITE SELECTION.......................................................................................................................................................................... 8 2.1. APPROPRIATE COMMUNITY SELECTION .................................................................................................................................. 8 2.2. SYSTEM ELEMENTS AND PROPER PLACEMENT .......................................................................................................................... 8

2.2.1. River Intake Examples......................................................................................................................................... 8 2.2.2. Spring intake tank placement........................................................................................................................ 10

3. DESIGNING A HYDRAULIC RAM PUMP SYSTEM............................................................................................................... 11 3.1. TOTAL WATER USAGE........................................................................................................................................................... 11 3.2. SITE SURVEYING.................................................................................................................................................................. 11 3.3. DRIVE PIPE ......................................................................................................................................................................... 11 3.4. LOCATE STANDPIPE OR DRIVE TANK ..................................................................................................................................... 11

4. SYSTEM EXAMPLE ................................................................................................................................................................... 14 4.1. SITE VISIT AND SOURCE SELECTION ...................................................................................................................................... 14 4.2. SELECTION OF RAM PUMP SITE............................................................................................................................................ 14 4.3. CALCULATION OF REQUIRED FLOW AND STORAGE TANK SIZING ........................................................................................... 14 4.4. CALCULATION OF AVAILABLE WATER................................................................................................................................... 15 4.5. FIRST ITERATION OF DESIGN TO IMPROVE FEASIBILITY ........................................................................................................... 16 4.6. CHECK DRIVE PIPE LENGTH IF STANDPIPE IS NEEDED ............................................................................................................. 16

5. PUMP INSTALLATION .............................................................................................................................................................. 18 5.1. PUMP FABRICATION............................................................................................................................................................ 18 5.2. PUMP MOUNTING AND ALIGNMENT..................................................................................................................................... 18 5.3. PUMP AND VALVE ASSEMBLY ............................................................................................................................................. 19

5.3.1. Impulse Valve ..................................................................................................................................................... 19 5.3.2. Delivery Valve Assembly ................................................................................................................................. 21

5.4. STARTING THE PUMP ............................................................................................................................................................ 21 6. OPERATIONS AND MAINTENANCE..................................................................................................................................... 22

6.1. GROUP TO MAINTAIN SYSTEM ............................................................................................................................................. 22 6.2. COMMON RAM PUMP MAINTENANCE PROBLEMS .............................................................................................................. 22 6.3. OPERATIONS AND MAINTENANCE WEEKLY CHECKS ........................................................................................................... 22

7. BIBLIOGRAPHY ........................................................................................................................................................................ 24 8. APPENDIX................................................................................................................................................................................. 25

8.1. EXAMPLES OF RAM PUMP INSTALLATIONS ........................................................................................................................... 25 8.2. RAM PUMP EXAMPLE SYSTEM DETAILS ................................................................................................................................ 27 8.3. S-2 RAM PUMP DESIGN CHANGES .................................................................................................................................... 36 8.4. S-2 RAM PUMP FABRICATION INSTRUCTIONS...................................................................................................................... 39

TABLE LISTING

TABLE 1 – BASIC SYSTEM DATA.............................................................................................................................................................. 14 TABLE 2 - DRIVE PIPE SIZING CHART ...................................................................................................................................................... 17

TABLE OF FIGURES

FIGURE 1 - RAM PUMP SYSTEM TERMS ..................................................................................................................................................... 2 FIGURE 2 - S-2 RAM PUMP ...................................................................................................................................................................... 3 FIGURE 3 - STEP 1 OF RAM PUMP CYCLE ................................................................................................................................................ 4 FIGURE 4 - STEP 2 OF RAM PUMP CYCLE ................................................................................................................................................ 5 FIGURE 5 - STEP 3 OF RAM PUMP CYCLE ................................................................................................................................................ 6 FIGURE 6 - STEP 4 OF RAM PUMP CYCLE ................................................................................................................................................ 6 FIGURE 7 - STEP 5 OF RAM PUMP CYCLE ................................................................................................................................................ 7 FIGURE 8 – RIVER INTAKE AND SETTLING TANK ......................................................................................................................................... 9 FIGURE 9 - SECTION THROUGH SETTLING TANK ........................................................................................................................................ 9 FIGURE 10 - (3) RAM PUMPS INSTALLED IN PARALLEL WITH A STREAM INTAKE .......................................................................................... 9 FIGURE 11 - (2) RAM PUMPS INSTALLED IN SERIES.................................................................................................................................. 10 FIGURE 12 - EXAMPLE SPRING INTAKE STRUCTURE.................................................................................................................................. 10 FIGURE 13 - STANDPIPE/DRIVE TANK PLACEMENT ................................................................................................................................. 13 FIGURE 14 - EXAMPLE OF STEEL RAM PUMP CRADLE USING 40MM STEEL ANGLE BARS ........................................................................ 19 FIGURE 15 - “NORMAL” RAM PUMP INSTALLATION ............................................................................................................................... 25 FIGURE 16 - RAM PUMP SYSTEM WITH DRIVE TANK (OR STANDPIPE) ...................................................................................................... 25 FIGURE 17 - RAM PUMP SYSTEM WITH STANDPIPE .................................................................................................................................. 26

Introduction As the world’s population continues its precipitous rise, the world’s resources are subject to ever increasing competition and price increases. Nations across the world are searching for alternative technologies that can move them towards energy independence. When the cost of electricity rises, so does the cost of pumped water. Hydraulic Ram Pumps are one of the oldest appropriate technologies pertaining to water, they require no electricity to operate, and are relatively low-maintenance. Developed in France in 1796 by the Mongolfier Brothers, the concept of the hydraulic Ram Pump has been applied worldwide in dozens of different configurations.

This manual is intended to assist experienced design engineers attempting to identify and construct a Hydraulic Ram Pump system for potable water or irrigation use. The specific device in question is an S-2 Ram Pump designed and tested by the Development Technologies Unit at the University of Warwick in the mid 1990’s. Inside are overviews of site selection, system design, pump fabrication and cost estimation. With confidence, the reader should have no problem designing, constructing and maintaining a rural water supply system. If this manual is found by a non-technical worker, they should seek the assistance of a design engineer in explaining and implementing the ideas within.

The information contained within this manual should be credited to the various development and extension departments at Clemson University in the USA, and the University of Warwick in the UK; his manual is merely a compilation and clarification of their work. In the Philippines, the Ram Pump design research developed by these universities was tested in a rural setting. The following agencies must also be thanked for their funding and support:

US Peace Corps

The Peace and Equity Foundation of the Philippines

Aquinas University of Legaspi, Albay

Alternative Systems for Community Development Foundation (ASCODE), inc.

The Municipal Government of Jovellar, Albay, Philippines

The Philippine Department of Social Welfare and Development: Kalahi: CIDSS Program

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1. The basics 1.1. What is a hydraulic Ram Pump?

A Hydraulic Ram Pump is a non-electric pump that uses the energy of a large amount of water falling to raise a small amount of water to a high elevation. Although originally designed for use in village water supply, Ram Pumps have been used successfully in agriculture as well. The Ram Pump is especially applicable for upland areas where water sources are strong but access is limited due to their distance from the users.

Ram Pumps have been used in both developed and developing countries worldwide for hundreds of years. The Ram Pump was invented in France in the 1700s and has seen widespread acceptance due to its relatively low operation cost and non-electric nature. Dozens of Ram Pumps have been installed in the Philippines in Bohol, Palawan and, as of 2008, Bikol.

Included in this manual are fabrication instructions for the S-2 Ram Pump, designed by the Development Technologies Unit of the University Of Warwick, England. The pump can be made at any machine shop with access to a lathe, drill press and welding machine.

1.2. Basic Terms

Figure 1 - Ram Pump System Terms

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Figure 2 - S-2 Ram Pump

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1.3. How does a Ram Pump Work?

The concept behind the ram idea is a “water hammer” shock wave. Water has weight, so a volume of water moving through a pipe has momentum. If a car runs into a brick wall the result is crumpled metal. If a moving water flow in a pipe encounters a suddenly closed valve, a pressure “spike” or increase suddenly appears due to all the water being stopped abruptly (that’s what water hammer is - the pressure spike).

Although this is a different model from the Ram Pump discussed in this manual, here’s how the Ram Pump actually works, step-by-step:

Figure 3 - Step 1 of Ram Pump Cycle

In Figure 3, Water (blue arrows) starts flowing through the drive pipe and out of the “waste” valve (#4 on the diagram), which is open initially. Water flows faster and faster through the pipe and out of the valve

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Figure 4 - At some point, water is moving so quickly through the brass swing check “waste” valve (#4) that it grabs the swing check’s flapper, pulling it up and slamming it shut. The water in the pipe is moving quickly and doesn’t want to stop. All that water weight and momentum is stopped, though, by the valve slamming shut. That makes a high pressure spike (red arrows) at the closed valve. The high pressure spike forces some water (blue arrows) through the spring check valve (#5 on the diagram) and into the pressure chamber. This increases the pressure in that chamber slightly. The pressure “spike” the pipe has nowhere else to go, so it begins moving away from the waste valve and back up the pipe (red arrows). It actually generates a very small velocity backward in the pipe.

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Figure 5 - As the pressure wave or spike (red arrows) moves back up the pipe, it creates a lower pressure situation (green arrows) at the waste valve. The spring-loaded check valve (#5) closes as the pressure drops, retaining the pressure in the pressure chamber.


Figure 6 - At some point this pressure (green arrows) becomes low enough that the flapper in the waste valve (#4) falls back down, opening the waste valve again.

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Figure 7 - Most of the water hammer high pressure shock wave (red arrows) will release at the drive pipe inlet, which is open to the source water body. Some small portion may travel back down the drive pipe, but in any case after the shock wave has released, pressure begins to build again at the waste valve (#4) simply due to the elevation of the source water above the ram, and water begins to flow toward the hydraulic ram again.

Water begins to flow out of the waste valve (#4), and the process starts over once again.

The ram pump will usually go through this cycle about once a second, perhaps somewhat more quickly or more slowly depending on the installation.

1.4. System Design Process

For a Ram Pump system to function well, it must be designed with careful consideration of the surrounding area and water requirements of the users. This is the design process we will follow in this manual:

1) Community identification, site selection and source flow measurement 2) Calculation of water requirements of community 3) Topographic surveying of site 4) Determining pump configuration 5) Calculation of available supply by Ram Pump 6) Pipe and tank sizing 7) System detailing (tanks, pipes, access points)

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2. Site selection 2.1. Appropriate community selection

As with any kind of infrastructure development, the community must be consulted first to determine project feasibility. Residents of poor, rural barangays have a good idea of their water problems, local water sources, water quality and seasonal variations in source flow.

Ram Pumps function by utilizing the energy of a large volume of falling water to pump a smaller volume of water far above the water source. In any site investigation for a Ram Pump installation, one should always be looking for water sources on steeply sloping ground. The S-2 Ram Pump is designed to function with drive heights of 2 to 15 meters and delivery heights of up to 100 meters. This Ram Pump design can use between 40 and 120 liters/min minute of water; any less than 40 liters/min and the pump may not function.

Ram Pumps can be powered by either flowing surface water (rivers and streams) or spring water. Spring sources usually have lower source flow, but the water will usually not need treatment to make it potable. Rivers and streams have high flow rates but usually have suspended sediments that will need to be settled out before the water can enter the Ram Pump. Water from rivers and streams is not potable, so a filtration or chlorination device will need to be installed to ensure the health of the users. Streams have the added danger of flooding and the risk of damage to the system. In general, river or stream intakes are best used for agricultural applications of Ram Pumps while spring sources are best for village water supply.

Once a site has been identified, a topographic survey must be conducted to calculate the exact elevation differences and distances between the intake box, the drive tank, the Ram Pump and the storage tank. On that site visit, the source flow rate should be determined as well.

2.2. System elements and proper placement

The system intake can be from any kind of surface or ground water, so long as the topography will allow for the vertical fall from the intake to the Ram Pump. The source flow should be captured in a retention tank to maintain a constant depth of water above the drive pipe intake. Also, a retention tank allows for the removal of trash and sediment from the system (Figure 8). More system installation examples can be found in Appendix 8.1.

2.2.1. River Intake Examples

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Figure 8 – River Intake and Settling Tank

Figure 9 - Section Through Settling Tank

Depending on the available flow rate from the water source and the local topography, Ram Pump installations can be configured in many different ways:

Figure 10 - (3) Ram Pumps Installed in Parallel with a Stream Intake

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Figure 11 - (2) Ram Pumps Installed in Series

2.2.2. Spring intake tank placement

Springs can be a good choice for a Ram Pump water source due to their potability and lack of silt.

Water that will be pumped must be captured in a sealed spring intake box first and then piped into the system. Spring sources are usually free of sediment and, if protected properly from runoff, can maintain good water quality with minimal maintenance.

Figure 12 - Example Spring Intake Structure

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3. Designing A Hydraulic Ram Pump System 3.1. Total water usage

Before any Ram Pump system can be designed, there are certain pieces of information that must be gathered:

1. The difference in elevation between the water source and the proposed Ram Pump site. 2. The difference in elevation between the Ram Pump and proposed storage tank. 3. The available flow rate of water from the source. 4. The required flow rate at the storage facility 5. The distance from the source to the Ram Pump site 6. The distance from the Ram Pump site to the storage facility.

Calculation of available water is in section 4.4

Note: This data gathered may be changed to increase Ram Pump output or decrease piping costs. Engineering design is an iterative process and these numbers can change to decrease the cost of the system.

3.2. Site Surveying

Since the initial guess for Ram Pump and storage tank location will not always be correct, it is very important to

3.3. Drive Pipe

The drive pipe runs from the water source directly into the Ram Pump. When the Ram Pump closes, the pressure wave disperses in this pipe, so it is important that this pipe be rigid. The more rigid the drive pipe, the more efficient the pump will be (and the more water that can be pumped to the storage facility).

The length of the drive pipe is based on the location of installation. For the pump to function efficiently (or at all) the drive pipe must fall within certain limits. The maximum and minimum lengths of drive pipe are based on the drive pipe length (L) and the drive pipe diameter (D). If the distance from the intake to the Ram Pump is longer than the maximum pipe length, a standpipe should be placed in the system.

3.4. Locate standpipe or drive tank

If the distance from the intake to the pump is longer than the maximum drive pipe length, the system needs a standpipe. Stand pipes are only necessary if the drive pipe will be longer than the recommended maximum length (for instance, in the previous example a stand pipe may be required if the drive pipe were to be 150 feet in length, but the maximum drive length was determined to be only 104 feet). The stand pipe - if needed - is

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generally placed in the line the same distance from the ram as the recommended maximum length indicated.

The stand pipe must be vertical and extend vertically at least 1 foot (0.3 meter) higher than the elevation of the water source - no water should exit the pipe during operation (or perhaps only a few drops during each shock wave cycle at most). The standpipe should be at least 1” larger than the drive pipe. The supply pipe (between the water source and the stand pipe) should be 0.5” larger than the drive pipe.

The reason behind this is simple - if the drive pipe is too long, the water hammer shock wave will travel farther, slowing down the pumping pulses of the ram. Also, in many instances there may actually be interference with the operation of the pump due to the length of travel of the shock wave. The stand pipe simply allows an outlet to the atmosphere to allow the shock wave to release or dissipate. Remember, the stand pipe is not necessary unless the drive pipe will have to be longer than the recommended maximum length.

Another option would be to pipe the water to an open tank (with the top of the tank at least 1 foot (0.3 meter) higher than the vertical elevation of the water source), then attach the drive pipe to the tank. The tank will act as a dissipation chamber for the water hammer shock wave just as the stand pipe would. This option may not be viable if the tank placement would require some sort of tower, but if the topography allows this may be a more attractive option.

Figure 13 shows the proper installation of a Ram Pump with a drive tank; the feed pipe follows the contour of the hill to get as close as possible to the Ram Pump before the drive tank.

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Figure 13 - Standpipe/Drive Tank Placement

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4. System example

This section is a guide through the design process for a basic Ram Pump system.

Table 1 – Basic System Data Ew Elevation of water source 500m Es Elevation of consumers/storage 525m Lr Distance from source to Ram

Pump 75m

Ls Distance from Ram Pump to consumers/storage

250m

Qs Minimum water source flow rate 1 liter/second Ps Current Population at Site 120ppl G Population Growth Rate 2.5% n Design life of system 10yrs

4.1. Site visit and source selection

In this example, the initial site selection and survey has been performed. Table 1 has the basic data to design this system. Due to seasonal variations in water supply, the minimum source flow rate is used.

4.2. Selection of Ram Pump Site

The Ram Pump must be placed from 2 to 10 meters below the elevation of the water source. Once the Ram Pump site is selected, the drive height and delivery height can be calculated.

Er = 496 m

Hd = Ew – Er (1)

Hd = 500m – 496m = 4m

Where: Hd = Drive Height (m)

Ew = Elevation of Water Source (m)

Er = Elevation of Ram Pump site (m)

4.3. Calculation of required flow and storage tank sizing

Pf = Ps * (1 + G)^n (2)

Pf = 120ppl * (1 + 2.5%)^(10yrs) = 154ppl

Where: Pf = Design population (ppl)

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Ps = Current Population (ppl)

G = Population Growth Rate (%)

N = Design life of system (yrs)

Per capita water use varies both by location (urban vs. rural) and type of water system (household connections vs. communal faucets). For the sake of the example, it is assumed that a single person uses 50 liters of water per day for all domestic purposes (drinking, cooking, bathing, laundry, etc.).

Vd = Pf * 50 l/ppd (3)

Vd = 154ppl * 50 l/ppd = 7700 liters/day

Qr = 7700 liters/day / 24 hrs/day / 60 min/hr / 60 sec/min = 0.089 lps

Where: Vd = Daily water usage (liters)

Pf = Design population (ppl)

Qr = Required flow rate at storage tank (lps)

4.4. Calculation of available water

Ram Pump efficiency has been determined by a number of research organizations to be between 33% and 66% depending on the quality of the installation. In this example, the Ram Pump will be 45% efficient.

The elevation difference between the water source and Ram Pump is called the “drive height”. The elevation difference between the storage tank and the Ram Pump is called the “delivery height.” The following equation gives an approximate flow rate at the storage tank:

Qa = Qs * e * (Ew – Er) / (Es – Er) (4)

Qa = 1 lps * 45% * (500 – 496) / (525 – 496) = 0.062 lps

Qa = 0.062 lps * 86400 sec / day = 5362 liters/day

Where: Qa = Water Available From Ram Pump (lps)

Qs = Minimum Water Source Flow Rate (lps)

e = Pump Efficiency (%)

Ew = Elevation of Water Source (m)

Er = Elevation of Ram Pump (m)

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Es = Elevation of Storage Tank/Consumers (m)

4.5. First Iteration of Design to improve feasibility

Qr = 0.089 lps (Water required based on number of users; section 4.3)

Qa = 0.062 lps (Water available from initial Ram Pump system configuration)

Since Qr > Qa, this system is currently unfeasible.

There are several ways to solve this problem:

1. If the source flowrate is large enough, add additional pumps in parallel to increase the amount of water delivered.

2. Decrease delivery height by building the storage tank at a lower elevation

3. Increase drive height by building the Ram Pump at a lower elevation

4. Decrease the per-capita water demand by making a system with communal faucets instead of household connections (Level III -> Level II)

In this design example the source flow rate is only at 1 lps so solution 1 is unfeasible. It is assumed that the storage tank cannot be moved to a lower elevation because of the location of the users, so solution 2 is unfeasible. Solution 3, increasing the drive height by lowering the Ram Pump site will be tested:

Equation 4 is solved to calculate the needed Ram Pump Elevation (Er) for the system to be feasible.

Qr = Qs * e * (Ew – Er) / (Es – Er)

Qr * (Es – Er) = Qs * e * (Ew – Er)

Qr * Es – Qs * e * Ew = Er * (Qr – Qs *e)

Er = (Qr * Es – Qs * e * Ew) / (Qr – Qs * e)

Er = (0.089 * 525 – 0.5 * 45% * 500) / (0.089 – 0.5 * 45%)

Er = 483 m

Ew - Er = 525 - 483 = 42m (New delivery height)

Es - Er = 500 - 483 = 17m (New drive height)

4.6. Check drive pipe length if standpipe is needed

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Next, the drive pipe must be sized and the length determined. Table 2 can be used to determine drive pipe size.

Table 2 - Drive Pipe Sizing Chart Source Flow Rate

(lps) Drive Pipe Diameter

(inches) 0.66 to 1 1”Ø 1 to 1.33 1.5”Ø 1.33 to 2 2”Ø

In this example, the minimum source flow rate is 1 liter/sec, so a drive pipe size of 1.5”Ø will be used. Using the drive pipe diameter, the drive pipe length must be checked. If the drive pipe is too long or too short, the ram shockwave will dissipate to quickly or too slowly and the pump may not function correctly, if at all.

LdMin = 150 x Dd (5)

LdMax = 1000 x Dd (6)

LdMin = 150 x 1.5” = 225” = 5.72m

LdMax = 1000 x 1.5” = 1500” = 38.1m

Lr = 75m (From Table 1)

Lr > LdMax; the drive pipe is too long; this system will need a standpipe

Where: LdMin = Minimum Drive Pipe Length (m)

LdMax = Minimum Drive Pipe Length (m)

Lr = Distance from water source to Ram Pump (m)

Since the distance from the source to the Ram Pump is longer than the maximum allowable length of the drive pipe, a standpipe must be placed in the system. The standpipe should be placed as far from the Ram Pump is possible to give the Ram Pump the maximum possible drive head.

In this case, the standpipe should be no farther than 38m from the Ram Pump. The actual location of the standpipe should be surveyed to determine its elevation.

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5. Pump Installation 5.1. Pump Fabrication

See Appendix 0 for full details on S-2 Ram Pump fabrication.

IMPORTANT NOTE: There are two sections of the pump fabrication manual, one is the original DTU design, the other is a page of design changes that should be considered before fabrication. Before attempting to fabricate a Ram Pump, both sections should be read thoroughly.

In Legaspi City, Albay, there is an experienced fabricator who has made 4 pumps without a problem:

Ravalo Machine Shop and Auto Supply Inc.

Circumferential Road, Capantawan, Legaspi City

Tel Nos. (052) 820-5445 or (052) 480-5115

5.2. Pump mounting and alignment

Ram Pumps should be securely fastened to a concrete or steel base to prevent them from moving. On every pump cycle, the pressure wave causes the pump to move and, If not properly secured, the pump will break and may damage the pipes as well. Figure 14 shows an example of a steel pump mount mounted in a concrete base. Pumps can also be mounted on stainless steel bolts embedded in a concrete base.

Remember: Any kind of pump mount should be aligned using the pump body to make sure the pump will fit. Without proper alignment, the pump will not fit and the base may have to be remade.

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Figure 14 - Example of Steel Ram Pump Cradle Using 40mm Steel Angle Bars

5.3. Pump and Valve Assembly 5.3.1. Impulse Valve

1. Look at the valve stem. The end with more threads will be for the bottom.

2. Tighten a nut down to the bottom of the long threads

3. Add a steel washer and then a rubber washer to the rod.

4. Place the first valve disc, then the valve rubber, then the second valve disc on the rod

5. Add a rubber washer and then a steel washer.

6. Add one nut to the threads and tighten it using your hand. Once it is tight, make one full turn with the wrench.

7. Add a second nut and lock them together.

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8. Place the valve rod through the valve plate and the stop bar with the short threads at the top.

9. Add washers for spacing and then 2 nuts.

10. Adjust the pump and then lock the nuts in place.

11. When the valve is closed, the nuts should be no more than 1cm above the top washer.

12. Test the valve by moving it up and down. It should move up and down easily, and without rubbing the sides of the stop bar.

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5.3.2. Delivery Valve Assembly 40mm M10 Bolt

Steel Washer Bolt

Rubber Washer

Valve disc (64mm Diameter, 3mm thick)

Steel Washer

Nuts

1. Clean off the delivery plate and remove any rust. 2. Place steel washer on bolt 3. Place rubber washer on bolt 4. Place valve disc on bolt. The disc should move freely up and down and not stick when placing it on the bolt. Make sure the smooth side is facing down! The valve may not work properly otherwise 5. Place the bolt through the delivery plate 6. Place a small steel washer on the bolt 7. Tighten one nut until the valve can move up and down 2mm. 8. Lock a second nut against the first.

5.4. Starting the pump

The pump will have to be manually started several times when first placed in operation to remove the air from the ram pump piping. Start the pump by opening all valves on the intake box, drive line and Ram Pump. Water will flow from the opening of the impulse valve until it suddenly shuts. Push the impulse valve open (it will be difficult, use your foot) and wait for it to shut again. You may have to push the impulse valve open repeatedly to re-start the pump in the first few minutes (10 to 20 times is not abnormal) - air in the system will stop operation until it is purged.

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6. Operations and Maintenance 6.1. Group to maintain system

Ram Pump systems can be designed and constructed quite cheaply and easily, but require constant maintenance. Over time, the moving parts and gaskets of the pump will wear out and need replacement. Pump repairs are not very complex and a community-based organization, if properly trained, can easily maintain the Ram Pumps for long periods of time. In addition, a local water and sanitation organization can collect a small fee from all water users to pay for replacement parts and an honorarium for the caretaker.

The system’s caretaker needs to live close enough to the system to check on the pumps at least twice a week. In rural areas, people often live near a source of water; caretakers who live closer to the pumps are more likely to visit and accept a sense of ownership over the system.

6.2. Common Ram Pump Maintenance Problems

The S-2 Ram Pump has been installed and tested in many different countries. Over time, a list of common problems was developed. These problems have been addressed in Appendix 0.

6.3. Operations and Maintenance Weekly Checks

The pump should be checked weekly, if possible, to keep it running consistently. All information should be recorded in a logbook so recurring problems can be identified. The basic monthly checks are as follows:

1. Intake Box a. Open the fittings and clean out any debris b. Fix trenches to divert water around the tanks

2. Ram Pumps - Open each Ram Pump and inspect each valve

i. Main valve: 1. Is the valve rod being worn down? 2. Valve rubber disc still in good condition? 3. Are the bolts tight? 4. Are the bolts/nuts rusty?

ii. Delivery valve 1. Can the valve move up and down about 2mm? 2. Are the nuts locked against each other? 3. Is the rubber disc intact? 4. Is there rust?

iii. Snifter valve 1. Is the small hole still sealed?

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2. Is the bolt tight? 3. Is the hole blocked?

iv. Bolts and gaskets 1. Oil all bolts and gaskets 2. Are the bolts and nuts rusty? 3. Are the gaskets in good condition?

3. Water Storage Tank

a. Measure water level b. Check for leaks. If there is a major leak, drain the tank and plaster the leaky

spot with cement. c. Check that the lid is on d. Repair trenches to divert water away from the tank (overflow, drain pipe)

4. Pipes

a. Walk pipe route and look for wet spots where the pipe may be leaking b. Drive Pipes c. Check pipe fittings for leaks d. Check pipe for excess movement during pump cycle

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7. Bibliography

Clemson University Cooperative Extension Service (2007). Home-made Hydraulic Ram Pump Retrieved September 21, 2008 from http://www.clemson.edu/irrig/equip/ram.htm

Lifewater: Water for the World. Designing a Hydraulic Ram Pump; Technical Note No. RWS.4.D.5. Retrieved September 21, 2008 from http://www.lifewater.org/resources/rws4/rws4d5.htm

University of Warwick Development Technologies Unit (1998). DTU Technical Release No. 14: The DTU S-2 Pump. Retrieved September 21, 2008 from http://www2.warwick.ac.uk/fac/sci/eng/research/dtu/lift/pubs/#tr

Thomas D. Jordan. A Handbook of Gravity-Flow Water Systems. Intermediate Technology Publications. London. 1984.

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http://www.clemson.edu/irrig/equip/ram.htm

http://www.lifewater.org/resources/rws4/rws4d5.htm

http://www2.warwick.ac.uk/fac/sci/eng/research/dtu/lift/pubs/#tr

8. APPENDIX

8.1. Examples of Ram Pump Installations

Figure 15 - “Normal” Ram Pump Installation

Figure 15 demonstrates the “normal” ram system where the drive pipe is less than the maximum length allowed. No stand pipe or open tank is required.

Figure 16 - Ram Pump System with Drive Tank (or Standpipe)

Figure 16 shows one system option where the drive pipe is longer than the maximum length allowed. The open water tank is required to allow dissipation of the water hammer shock wave.

25

Figure 17 - Ram Pump System with Standpipe

Figure 17 is another option used where the drive pipe is longer than the maximum length allowed. The stand pipe (open to atmosphere at the top) is required to allow dissipation of the water hammer shock wave.

26

APPENDIX 8.2. Ram Pump Example System Details

8.2.1. RP1 - Ram Pump Fitting Detail 8.2.2. RP2 - Ram Pump Enclosure Detail 8.2.3. RP3 - 9000L Reservoir Detail 8.2.4. RP4 - Communal Faucet Detail 8.2.5. Bill of Materials for Example System

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Name of Project:Location:

GENERIC RAMPUMP WATER DELIVERY DISTRIBUTION SYSTEM 1/411:22 AM, 1/7/2009

A DIRECT COST1 INTAKE BOX

Quantity 0.87 m^3

Materials:9 bags Portland Cement @ 220.00 /bags 1,980.00

0.50 m^3 Sand @ 250.00 /m^3 125.00 0.80 m^3 Gravel @ 350.00 /m^3 280.00

14 pcs 10mm RSB @ 200.00 /pcs 2,800.00 7 kg 16 ga Tie Wire @ 75.00 /kg 525.00 6 pcs 1/4" Ordinary Plywood @ 500.00 /pcs 3,000.00

18 pcs 2x2x12' Cocolumber @ 40.00 /pcs 720.00 6 kgs Assorted Nails @ 50.00 /kgs 300.00 3 pcs 2"Ø S-40 GI Nipple (8" Long) @ 200.00 /pcs 600.00 1 pcs 2"Ø HDP to GI Male Compression Fitting @ 150.00 /pcs 150.00 1 pcs 2"Ø S-40 GI Cap @ 50.00 /pcs 50.00

Materials Cost P 10,530.00 Labor:

1 lot Labor Cost (50% of materials budget) @ 5,265.00 /day 5,265.00 Labor Cost P 5,265.00

Materials Cost P 10,530.00 Labor Cost P 5,265.00 Item Cost P 15,795.00

Unit Cost 18,197.00 /m^3

2 RAMPUMP BOXQuantity 0.9 m^3 of conc

Materials:9 bags Portland Cement @ 220.00 /bags 1,980.00

0.50 m^3 Sand @ 250.00 /m^3 125.00 0.80 m^3 Gravel @ 350.00 /m^3 280.00

14 pcs 10mm RSB @ 200.00 /pcs 2,800.00 7 kg 16 ga Tie Wire @ 75.00 /kg 525.00 6 pcs 1/4" Ordinary Plywood @ 500.00 /pcs 3,000.00

18 pcs 2x2x12' Cocolumber @ 40.00 /pcs 720.00 6 kgs Assorted Nails @ 50.00 /kgs 300.00 4 pcs 1/2"Ø Stainless Bolt (4" Long) @ 50.00 /pcs 200.00 4 pcs 1/2"Ø Washer @ 10.00 /pcs 40.00 4 pcs Nut for 1/2"Ø Bolt @ 10.00 /pcs 40.00 3 pcs 2"Ø S-40 GI Nipple (8" Long) @ 200.00 /pcs 600.00 1 pcs 2"Ø S-40 GI Cap @ 50.00 /pcs 50.00




Unit Cost 18,421.66 /m^3

DETAILED COST ESTIMATE AND BILL OF MATERIALS

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3 DRIVE PIPE AND STANDPIPEQuantity 42 lin m

Materials:60 m 2"Ø HDP SDR-11 Pipe @ 150.00 /m 9,000.00 1 pcs 2"Ø HDP to GI Male Compression Fitting @ 100.00 /pcs 100.00 1 pcs 2"Ø GI S-40 Nipple (8" Long) @ 200.00 /pcs 200.00 1 pcs 2"Ø GI Tee @ 100.00 /pcs 100.00 2 pcs 2"Ø GI S-40 Nipple (4" Long) @ 100.00 /pcs 200.00 1 pcs 2.5"Ø to 2"Ø GI Reducer @ 100.00 /pcs 100.00 3 m 2.5"Ø GI S-20 Pipe @ 490.00 /m 1,470.00 1 pcs 2"Ø to 1.5"Ø GI Reducer @ 75.00 /pcs 75.00 7 lngth 1.5"Ø GI S-40 Pipe @ 1,132.00 /lngth 7,924.00 2 pcs. 1.5"Ø GI Union @ 65.00 /pcs. 113.75 5 pcs. 1.5"Ø GI Coupling @ 25.00 /pcs. 131.25




Unit Cost 693.36 /lin m

4 RAMPUMPS AND FITTINGS (1.5"Ø Drive Pipe)Quantity 1 Rampumps

Materials:1 pcs. 1" Hydraulic Rampumps (Fabricated Locally) @ 16,000.00 /pcs. 16,000.00 1 pcs 1.5"Ø S-40 GI Nipple (4" Long) @ 70.00 /pcs 70.00 1 pcs 1.5"Ø GI Gate Valve 1,500.00 /pcs 1,500.00 1 pcs 1.5"Ø S-40 GI Nipple (12" Long) @ 150.00 /pcs 150.00 1 pcs 2"Ø to 1.5"Ø GI Reducer @ 70.00 /pcs 70.00 1 pcs 3/4"Ø GI Union @ 50.00 /pcs 50.00 2 pcs 3/4"Ø S-40 GI Nipple (4" Long) @ 40.00 /pcs 80.00 1 pcs 3/4"Ø GI Ball Valve @ 285.00 /pcs 285.00 1 pcs 3/4"Ø HDP to GI Male Compression Fitting @ 150.00 /pcs 150.00 1 lot Additional Valve Rubber @ 500.00 /lot 500.00


1 lot Labor Cost (50% of materials budget) @ 9,427.50 /lot 9,427.50 Labor Cost P 9,427.50


Unit Cost 28,282.50 /rampump

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5 DELIVERY LINES FROM PUMPS TO TANKQuantity 250 lin m

Materials:250 m SDR-11 HDP Pipe (3/4") @ 38.84 /m 9,710.00

6 pcs. 3/4"Ø HDP to GI Male Compression Fitting @ 200.00 /pcs. 1,200.00 1 pcs. 3/4"Ø HDP to GI Male Compression Elbow @ 112.00 /pcs. 112.00 6 rolls Teflon Tape 1/2" @ 25.00 /rolls 150.00


1 lot Labor Cost (50% of materials budget) @ 5,586.00 /lot 5,586.00 Labor Cost P 5,586.00



6 9000 LITER FERROCEMENT RESERVOIR1 EXCAVATION

Quantity 2 m^3

Labor: 1.125 m^3/manday Productivity1 1 days Skilled Laborer @ 250.00 /day 250.00 1 1 days Common Laborer @ 150.00 /day 150.00

Labor Cost P 400.00

Labor Cost P 400.00 Item Cost P 400.00

Unit Cost 200.00 /m^3

2 CONCRETE WORKSQuantity 1 TanksMaterials:

25 bags Portland cement @ 185.00 /bags 4,625.00 0.83 m³ Sand @ 200.00 /m³ 166.00 0.21 m³ 1/2" Gravel @ 475.00 /m³ 99.75

17 bags Waterproofing Compound @ 20.00 /bags 340.00 29 kg 16 ga Tie Wire @ 50.00 /kg 1,450.00 4 pcs 8mm rebar @ 150.00 /pcs 600.00

35 pcs Rice Sacks @ 10.00 /pcs 350.00 1 pcs 150mm Stainless Steel Nipple (1 1/2"Ø) @ 150.00 /pcs 150.00 2 pcs 150mm Stainless Steel Nipple (1"Ø) @ 140.00 /pcs 280.00 1 pcs 150mm Stainless Steel Nipple (3/4") @ 130.00 /pcs 130.00 2 pcs 150mm Stainless Steel Nipple (1.2") @ 120.00 /pcs 240.00 5 rolls Teflon Tape @ 50.00 /rolls 250.00 1 pcs 1.5" Gate Valve @ 2,000.00 /pcs 2,000.00 1 pcs 1" GI Cap @ 750.00 /pcs 750.00


3 7 days Skilled Mason @ 250.00 /unit 5,250.00 5 7 days Common Laborer @ 150.00 /unit 5,250.00

Labor Cost P 10,500.00


Unit Cost 21,930.75 /Tank34



7 DISTRIBUTION LINE TO CONSUMERSQuantity 300 lin m

Materials:300 m 1.5" SDR-11 HDP @ 80.00 /m 24,000.00





8 COMMUNAL FAUCETSQuanity 3 TapsMaterials:

3 pcs S40 GI Faucet, 0.5" @ 250.00 /pcs 750.00 1 lngth 0.5" S40 GI Pipe, 6m lengths @ 180.00 /lngth 180.00

15 mtrs. 0.5" SDR-11 HDP Pipe @ 24.50 /mtr 367.50 3 pcs S40 GI Ball Valve 0.5" @ 250.00 /pcs 750.00 3 pcs S40 GI Elbow, 0.5" @ 25.00 /pcs 75.00 3 pcs S40 GI Tee (Threaded) @ 25.00 /pcs 75.00 3 pcs HDP Compression Fitting (0.5") @ 90.00 /pcs 270.00 3 pcs HDP Saddle Clamp (1.5" to 0.5") @ 200.00 /pcs 600.00 3 pcs 0.5" Water Meter @ 600.00 /pcs 1,800.00 3 bags Portland Cement @ 188.00 /bag 564.00

0.255 m^3 Sand @ 200.00 /m^3 51.00 0.51 m^3 Gravel @ 475.00 /m^3 242.25

6 pcs 10mm Rebar (6m pieces) @ 100.00 /pcs 600.00 3 shts 1/4" Ordinary Plywood @ 500.00 /sht 1,500.00 3 pcs Hacksaw Blade @ 50.00 /pcs 150.00 6 kg Asst Nails @ 50.00 /kg 300.00



Materials Cost 8,274.75 Labor Cost P 4,137.38 Item Cost P 12,412.13

Unit Cost 4,137.38 /Stand

Total Materials Cost P 114,336.50Total Labor Cost P 62,352.88

Total Direct Cost P 176,689.38

Contingency10% Contingency P 17,668.94

Total Project Cost P 194,358.31

35

APPENDIX

8.3. S-2 Ram Pump Design Changes

36

APPENDIX

8.4. S-2 Ram Pump Fabrication Instructions

39

hydraulic ram pump system design manual - us peace corps, philippines

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