Career Episode -3
Third career episode is based on my project ‘THE DESIGN AND INSTALLATION OF WINDMILL POWERED WATER PUMP’.
The project was initiated by me
when I was doing my B tech in Mechanical Engineering. The project duration was 3 month and carried out from March 2011 to
June 2011. The project was carried out
for the partial fulfilment of the requirements for the award of the degree of Bachelor
of Technology. The project was based in my college, Toc H
institute of Science and Technology Kochi, India.
H Institute of Science and Technology is one of the leading professional college
in the country affiliated to Cochin Univeristy of Science and Technology. In
household electrical consumption a lion’s share of the usage goes for pumping
water from the well to storage tanks. If this can be substituted with a wind
mill water pump a good amount can be saved on the monthly electric bill. Wind mills are a non-conventional source of producing
power and it is considered as one of the most potential source of energy. The
aim of my project was to design, fabricate and install a wind mill as a source
of generating power for running a water pump.
I have performed the following tasks during the project;
and prepared a project synopsis.
the project for timely completion.
the entire system and prepared necessary mathematical calculations.
the cost estimation for fabrication and installation.
Prepared a block diagram of the system using AUTOCAD
the materials after detailed research.
the fabrication processes.
with civil department regarding the construction of foundation.
the installation of the system and conducted trial run.
regular project meetings with the project guide and the team
detailed project report
Below is the hierarchy of the project with clear demonstration of
c) Personal Engineering Activity
I started the
project with a detailed
study about wind mills and its components, water pump and other components. A
detailed study was conducted on the availability of wind and power that can be
trapped by wind mills. After initial study, I prepared a synopsis indicating
the objectives, components to be used, expected power generation and estimated
cost. This has been then submitted for the approval of Department head and
project guide along with the project planning draft. After the approval I
proceed further towards the design of the system.
I designed the system consists of a high solidity multi-vane wind
rotor, drive shaft, crank, connecting rod and a reciprocating pump. Rotary
motion of the windmill rotor is translated to reciprocating motion of the
connecting rod by the crank. The connecting rod operates the pumps piston up
and down through the cylinder during its strokes. Two check valves, both
opening upwards, are fitted on the piston and the bottom of the pump. These
valves allow the flow only in upward direction. When the connecting rod drives
the piston in the upward direction, the piston valve is closed and thus the
water column above the piston is lifted up, until it is delivered out through
the discharge line. At the same time, suction is created below the piston,
which causes the suction valve to open and thus fresh water from the well enter
into the space below. During the downward stroke, the piston valve is opened
and the suction valve is closed. The water collected below the piston thus
enters into the space above, through the piston valve. These cycles are
repeated resulting in pulsating sinusoidal water discharge from the system.
The main difficulty faced during the design was the
design of blades. Just like an
aeroplane wing, wind turbine blades work by generating lift due to their shape.
The more curved side generates low air pressures while high pressure air pushes
on the other side of the aerofoil. The net result is a lift force perpendicular
to the direction of flow of the air. The dimensions of blades were fixed after calculating
the power required to run the pump. The required suction head and delivery head
of the pump is taken into account to calculate the power input required for the
pump. Then I calculated the required diameter of the wind mill turbine. The pump
chosen was a reciprocating pump since its efficiency is more compared to
centrifugal pump; Reciprocating
pumps utilize the principle of a moving piston, plunger, or diaphragm to draw
liquid into a cavity through an inlet valve and push it out through a discharge
Then I calculated the dimensions of the drive shaft,
which is to be used to carry the power produced by wind mill to run the pump.
The dimensions were calculated by taking the expected load on the shaft
account. After the design of components, I prepared a block diagram of the
system indicating the dimensions using AUTOCAD. Then I formed a team for
fabrication with experts from the field of welding, molding. The material
requirement was calculated with the help of an expert team and purchased
ensuring the quality. I arranged all the tools and equipment’s before the
beginning of fabrication and ensured the availability of required labor force.
A planning was drafted for the fabrication and installation process and it was
aimed to complete within 45 days.
The fabrication was started by molding the turbine
blades as per the design. The location for the wind mill was already selected
as per the flow of wind. I consulted with the civil department for the
construction of foundation for the wind mill. Then the components of the wind
mill are joined together by welding. The pump was erected at a concrete
platform. The drive shaft was fabricated in a local workshops and it is then
connected both to the wind mill and pump through slider crank mechanism. I
consulted with senior engineer of a contracting firm for practical solutions
throughout the installation process.
After installation, I performed detailed inspection
and checked the position of all the mechanical components. Then I consulted
with my project guide and department head and fixed a time for the trial run.
During the trial run, all the people worked behind the project were present. I
controlled the trial run and ensured safety. The trial run was a success and
the system worked as desired.
The main difficulty faced during the installation was
to ensure the proper joining of components. I ensured it by careful inspection
and declared that the entire system is strong and safe. A team of experience in
installing heavy equipment helped me a lot in finding practical solutions to
problems raised. I monitored the precautions to be taken care during fabrication
and installation. I ensured that the workers are strictly following the safety
principles and using the safety equipment’s when ever required.
Another difficulty was to build a strong foundation for both the
wind mill and pump. This is essential since the machines are vibrating while
working. The civil engineering department helped me on this and they designed and
built strong foundations.
This project was a challenging one and I was able
to make it a success. This is achieved as a result of detailed background
study, well coordination with other departments and above all with the
dedication of my team. I applied the knowledge gained from my studies
especially from the workshops and practical sessions. My knowledge in the field
of design of engineering components, fabrication processes, engineering
drawing, material planning, working of different machines and practical
knowledge on installation helped me to accomplish my aim. My department head
and project guide was with me every time and provide advice and suggestions.
I prepared a detailed project report after the success of my
project. I drafted the literature survey, specification and working of machines
used, overall processes, challenges faced and solutions implemented, design
calculations, drawing, cost analysis, suggestions for improvements, critical
findings and recommendations for maintenance and photos. The purchasing of
materials and other expenses were through proper channels. In addition to the evolution of a
successful design for using a non-conventional energy source, the project days
were helpful in building me especially by enhancing my engineering knowledge.