A

Project Report
On
DESIGN AND DEVELOPMENT OF SOLAR RECIPROCATING
PUMP
In partial fulfillment of the

Academic requirement for award of

Bachelor of technology in

Mechanical Engineering

Submitted

BY

SHANTANU KUMAR JENA (15621A0318)

MOHAMMED ABDUL RAZZAK (15621A0313)

MUJTABA MOHAMMED (16625A0315)

UNDER THE GUIDANCE OF

U.M. CHAUDHARY

Professor

Department of Mechanical Engineering

Aurora’s Engineering College.

(Affiliated to JNTU, Hyderabad)

Bhongir-508116

1
 2015-2019

​Aurora’s Engineering College.

(Affiliated to JNTU, Hyderabad)
Bhongir-508116
2015-2019

CERTIFICATE

This is to certify that the project report entitled ​Design and development of solar
reciprocating pump ​that is being submitted by

SHANTANU KUMAR JENA (15621A0318)

MOHAMMED ABDUL RAZZAK (15621A0313)

MUJTABA MOHAMMED (16625A0315)

In partial fulfillment for the award of the degree of bachelor of technology in

mechanical engineering to the Jawaharlal Nehru university is a record of bonafide
work carried out by Him under my guidance and supervision. The results embodied in
this project not been submitted to any other University or Institute for the award of
any degree or diploma.

INTERNAL GUIDE EXTERNAL GUIDE

2
HEAD OF DEPARTMENT PRINCIPAL

3
 ​DECLARATION

DESIGN AND DEVELOPMENT OF SOLAR RECIPROCATING PUMP

submitted to the JNTUH, recorded of an original work done by us under the guidance
of DR.U.M. Choudhary professor of AURORA ENGINEERING COLLEGE,
Bhongir and this project work has not performed the3 basis for the award of any
Degree or Diploma and similar project if any.

SUBMITTED BY

SHANTANU KUMAR JENA (15621A0318)

MOHAMMED ABDUL RAZZAK (15621A0313)

MUJTABA MOHAMMED (16625A0315)

4
 ​ACKNOWLEDGEMENT

Gratitude takes three forms-a feeling from heart , an expression in words and giving a
return. We take this opportunity to express our heartfelt feelings.

This satisfaction and euphoria that accompany a successful competition of any task
would be without the mention of the people incomplete without the mention of the
people who made it possible, with whose constant guidance and encouragement
crowned our efforts with success.

We consider it as our privilege to express our gratitude and respect to all those who
guided and inspired in the completion of this project.

Our sincere thanks to Dr UM CHOUDHARY who was with u8s at every stage till the
completion of our project in spite of his busy schedule. His vision discourages and
energy propelled us when the going seemed though. We bare gently indebted for his
valuable, constructive and critical guidance during this project.

We place on record our profound gratitude to Dr. LAKSHMANASWAMY Head of

Department of Mechanical Engineering in ensuring every possible assistance to us.
His contribution is unforgettable. His immense knowledge and amiable nature were of
great use in completing our project.

We thank the management , principal, administration and all our friends for providing
the necessary support and constant source of encouragement throughout our study at
AURORA ENGINNERING COLLEGE.

5
 ​ ​INDEX

CONTENT​ ​PAGE NO

Abstract

Chapter-1

1.1 Introduction 1
1.2 Importance or significance 4

Objective 5

Chapter-2

LITERATURE REVIEW

2.1 system overview 6

2.2 control technique 6

Chapter-3

DESIGN AND EXPERMENTATION

3.1 Working principle 10

3.2 Components 12

3.3 component specification 13

3.3.1 Solar panel 13

3.3.2 Battery 15

3.3.3 DC Motor 16

3.3.4 Piston cylinder 17

3.3.5 Suction and delivery pipes 18

6
 3.3.6 Circular disc 19

3.3.7 Connecting rod 21

3.3.8 Switch & wire 22

3.3.9 Base frame 22

Chapter-4

FABRICATION

4.1 Base frame 24

4.2 Connecting rod 26

4.3 Circular disc 27

4.4 Final assembling 28

Chapter-5

TESTING & CALCULATION

5.1 Testing 33

5.2 calculations 34

5.2.1 Discharge 34

5.2.2 Pressure & speed 34

5.2.3 Power 35

5.2.4 Torque 36

5.2.5 Discharge and efficiency 36

5.3 Cost estimation 39

5.3.1 Cost of material 39

7
 5.3.2 Machinning cost 39

5.3.3 Cost of standard parts 40

Chaper-6

SCOPE & APPLICATION

6.1 Application of reciprocationg pump 41

6.2 Advantages 42

6.3 Disadvantages 43

6.4 Problem identification 43

6.5 Key aspects and scope 44

FUTURE EXTENSION

Chapter-7

CONCLUSION

7.1 Conclusion 48

7.2 References 49

8
9
 ​LIST OF FIGURES

FIFURES​ ​PAGE

1.1 Rerciprocating pump 2

3.1 Working of reciprocating pump 10

3.2 Solar panel 14

3.3 Battery 15

3.4 DC Motor 16

3.5 Piston cylinder 18

3.6 Pipes 19

3.7 Connector 19

3.8 Circular disc 20

3.9 Connecting rod 21

3.10 Switch and wire 22

3.11 Base frame 23

4.1 Cutting process 24

4.2 Welding 25

4.3 Base frame 26

4.4 Connecting rod 26

4.5 Circular disc 27

4.6 Connection of Solar panel 28

4.7 Connection of piston and cylinder 29

10
4.8 Motor with disc 30

​LIST OF TABLES

TABLE NAME PAGE

3.1 Motor specification 17

3.2 Piston & cylinder specification 18

3.3 Disc specification 20

3.4 Connecting rod specification 21

5.1 Panel charging time 38

5.2 Cost of material 39

5.3 Machinning cost 39

5.4 cost of standard parts 40

11
 ABSTRACT
​

In present days, people need more and more power for driving instruments. A solar
based reciprocating pump is a pump, running on electricity on electricity generated by
solar cell, available from collected sunlight as opposed to greed electricity or diesel
run water pump. Nowadays many types of pump are available such as, positive
displacement pump, impulse pump, velocity pump, gravity pump, steam pump, valve
less pump. A reciprocating pump is class of positive displacement pump, is used for
variety of purpose such as, car washing, irrigation, color spraying, extraction of oil
from bottom of the earth, large fountain, garden water pump, etc. If 50% of the diesel
pump were replaced with solar PV pump set, diesel consumption could be reduced to
the tune of about 225 billion liter/year.

A solar reciprocating pumping systems is believed to be applicable to

many remote and domestic irrigations applications without access to electricity
relaying diesel power and having insufficient wind for pumping and to be cost
competitive, locally manufacturable alternative to photovoltaic. This system consists
of solar collector, battery, motor, crankshaft, reciprocating pump, valve and tank.

12
 ​CHAPTER-1

INTRODUCTION

1.1 INTRODUCTION

A solar powered pumping system methods needs to take account of the fact that
demand for irrigation system water will vary throughout the year. Peak demand
during the irrigation system season is often more then twice the average demand. This
means that solar pumps for irrigation are under utilized for most of the year. Attention
should be paid to the system of irrigation water distribution and application to the
crops. The irrigation pump system should minimize water losses, without imposing
significant additional head on the irrigation pumping system and be low of cost.
There are several technology alternatives for supply power or lift to groundwater
systems including wind turbines, windmills, generators, solar arrays, and hand
powered pumps. The main driving factors for selecting the appropriate technology are
regional feasibility, water demand, systems efficiencies, and initial and long term
costs. Other factors often include the need for power and water reserves in the form of
batteries and storage tanks Solar powered systems are often considered for use in
developing countries instead of other forms of alternative energy because they are
durable and exhibit long term economic benefits.

Solar powered water pumping has been recognized as suitable solution for grid
isolated rural locations in poor countries where there are high levels of solar radiation.
Solar powered water pumping systems can provide drinking water without the need
for any kind of fuel or the extensive maintenance required by diesel pumps . SPPS is

1
also not adequate for large scale irrigation, but can work for small scale drip irrigation
systems. A large scale SPPS can be considered one that serves over 240 peoples.
Photovoltaic solar panels are often used for agricultural operations, especially in
remote areas or where the use of an alternative energy source is desired. In particular,
they have demonstrated time and time again to reliably produce sufficient electricity
directly from solar radiation to power livestock and irrigation watering systems.

Solar water pumps may be especially useful in small scale or community based
irrigation, as large scale irrigation requires large volumes of water that in turn require
a large solar PV array. As the water may only be required during some parts of
theyear, a large PV array would provide excess energy that is not necessarily required,
thus making the system inefficient. Solar PV water pumping systems are used for
irrigation and drinking water India. The majority of the pumps are fitted with a 200
watt-3000watt motor that receives energy from a 1800 Wp PV array. The larger
systems can deliver about 140000 liters of water/day from a total head of 10 meters.

2
 Fig 1.1 (reciprocating pump)

In Today’s world there are many areas where drinking water is problem. In most of
the case hand pumps are used at villages and remote places to solve the problem.
There are operated with hands .It is difficult to operate it for children and women as it
consumes human power.

Solar power is one of the alternatives but is costly and unaffordable. This research
work through innovative ideas have tried to combine human power and solar pv

3
hybrid system with pendulum mechanism. The mechanism developed helps
store pendulum kinetic energy in fly wheels and converts oscillatory motion in
to smooth reciprocating motion to lift water .A small push required to continue the
oscillatory motion is given by a motor run on small solar pv panel. The pendulum
based water pump can be useful in the areas where electricity is not available.
Specially in India there are still many places where electricity and drinking water
systems are not as they are in other developed countries. This pump can solve
there problem of drinking water as they can use this mechanism to pump the water
under the earth’s surface​ .

The pendulum based hybrid water pump works on the principal of

Simple Harmonic Motion. The Simple Harmonic Motion is the motion in which
restoring force is directly proportional to the displacement. When the system is
displaced from its equilibrium position, a restoring force which resembles Hooke's
law tends to restore the system to equilibrium.

At the same time, counterweights or flywheels are also rotated simultaneously. The
counterweights are arranged in such a way that, when one weight will come up at that
time second will be go down. Also vice-versa, so some torque will be also generated
by these counterweights. Now, the combine power produced by pendulum, electric
motor & counterweights is given to the pump through transmitting mechanism used in
the system. It will transmit this combined power to reciprocating single acting type
water pump. So, by using this power, pump will pump the water from desired head &
produce particular discharge. By using this hybrid pendulum based water pump. We
can continuously pump the water upto 3 hours & 30 minutes, because battery will be
gets discharged in same time. In order to charge this 12V, 7A battery on 10W solar
panel is used. It can fully charged the battery in four hours.

4
1.2IMPORTANCE OR SIGNIFICANCE

The cost of this pumping system is very low as compare with solar water pumping
system. It is also possible to use such pumping system for irrigation purpose where
the electricity is not available because this hybrid solar pump does not require any
supply of electricity so it help to farmer to avoid the problem of load shading. The
overall system is energy efficient because for keeping pendulum in continuous
motion a small capacity 12 V 3A motor is used . The mechanism used is simple and
easy to understand. So the hybrid solar water pumping based on pendulum stored
energy is ecofriendly and play very important role in future as the sources of
conventional energy is depleting soon.

5
 ​OBJECTIVE

OBJECTIVE OF PAPER

● To develop continuous pumping system without use of electricity.

● To analyze the system techno economically with solar PV pumping system.
● To achieve the least cost
● To develop mechanism with least wastage of energy.

MINIMIZATION OF COST

The solar reciprocating pump will work without normal electricity. It will work
by DC current produced by solar energy. The maintenance cost for the regular
reciprocating pump will be more due to consumption of electricity. But for solar
reciprocating pump there will be very less maintenance cost comparative to regular
pump.

REDUCE WASTAGE OF ENERGY

In present days the consumption of electric power is increasing rapidly. The

main sources of electric energy are water and coal. 60% of electricity is produced by
coal. The availability of coal is decreasing very fast. In next 20 years all the coal will
be finished from earth. The use of renewable energy is the better option for the future.
In renewable energy sources the solar energy is highly available . the use of solar
energy will reduce the high consumption of regular electricity.

6
 ​CHAPTER-2

LITERATURE REVIEW

System Overview

Photovoltaic water pumping system are comprised of various segments. There is a

photovoltaic array which changes over solar energy straight forwardly into
electricity as DC. The pump will have an electric motor to drive it. The attributes
of these segments should be coordinated to get the best performance. The pump
motor unit will have its own particular ideal speed and stack contingent upon the
sort and size of the pump. Motor can be DC or AC. On the off chance that an AC
motor is utilized then an inverter is likewise required. Ac motors are all the more
broadly accessible. Inverters have gotten to be modest and proficient and solar
pumping system use exceptional electronically controlled variable-frequency
inverters which will improve coordinating between the panel and the pump. The
most effective kind of DC motor is a permanent magnet motor, These are getting
to be mainstream in solar pumping system.

All present day, commercial PV devices use silicon as the base material,
basically as mono crystalline or multicrystalline cells, however all the more as of
late additionally in amorphous structure. Different materials, for example, copper
indium dieseline and cadmium telluride are being produced with the point of
decreasing expenses and enhancing efficiencies. An array can change from maybe
a couple modules with a yield of low or less, to an immeasurable bank of a few
kilowatts or even megawatts.

Control Technique/ Method/Strategy

​Ideas identified with the sun oriented vitality have always been under overwhelming
innovative work. The essential goal is to improve the vitality delivered from
photovoltaic cells, by making the general frameworks more productive and cost

7
 effectives. Here different processes are proposed to achieve the efficient water
pumping system followed by technology regarding to its system components.

Malawi Solar Powered Water Pump System BY:- Hunter King1 and
Dr. Andre Butler2:

​This project will consist of a water pumping system to supply potable water to an
orphanage located in the Chuluchosema community of Malawi, Africa. The water
will be pumped from a nearby well up to a water tower located in the orphanage
center. The pump will be powered by a solar panel that will capture the solar
energy from the sun. This project is in association with Mercer’s University’s
Master’s Program for Environmental Engineering and Mercer on a Mission.

The water pump system will be built on Mercer’s campus and will then be sent to the
orphanage in Malawi to be assembled permanently. The water pumping system
will be built by materials that are sustainable enough to allow the system to
function properly long after the student has installed the system and has left. The
intent of this project is to provide a hands-on experience for the graduate student
by working with various professors and manufacturers as well as different
contacts from the developing country. The goal of this project is to supply potable
water to an orphanage without the residents retrieving it from a well.

Experimental Study Of Solar Water Pump BY:- Master of Science

Erin Williamson:

8
Bio resource Engineering Solar water pump studies for small-scale irrigation is a well
established procedure on many farms in western Canada and is practiced on
various levels around the world. It allows diversification of crops,

while increasing crop yields. However, typical irrigation systems consume a great
amount of conventional energy through the use of electric motors and generators
powered by fuel. The overall objective of this research was to determine the
feasibility of using photovoltaic (PV) modules to

power a water pump for a small-scale drip irrigation system in Montréal (Québec,
Canada). The study involved field observations, as well as computer simulations
of global solar radiation and PV electrical output. Field observations involved a
summer and winter installation of two amorphous silicon 42 W PV modules,
directly connected to a 12 V surface water pump.

​The parameters monitored were voltage, current,

back-of-panel temperature, pressure, and flow. These observed parameters were
used to determine PV electrical output and volume of water pumped. Site latitude,
elevation, and panel tilt were applied to the solar radiation and PV electrical
output models, along with the following meteorological data: daily average,
maximum, and minimum temperatures, and global solar radiation. Daily solar
radiation prediction showed a linear correlation of 0.69 with the observed daily
values, over the years 2000 to 2005. The correlation coefficient was improved to
0.91, when 7 day moving averages of both the observed and predicted solar
radiation data were used. PV electrical output and volume of water pumped were
monitored between August 2005 and May 2006. Both the power and water output
observations were less than expected. However, the predicted daily PV electrical
output ranged from 1.0 MJ d-1 in the summer to approximately 0.6 MJ d-1 in the
winter. As expected, an increase in power caused an increase in the volume of
water pumped​.

9
Solar water pumping; Pump; Photovoltaic; Efficiency; BY:- Brian
D Vick , R. Nolan Clarck:

​For several years, many types of solar powered water pumping systems were

evaluated, and in this paper, diaphragm and helical solar photovoltaic (PV)
powered water pumping systems are discussed. Data were collected on diaphragm
and helical pumps which were powered by different solar PV arrays at multiple
pumping depths to determine the pumping performance, efficiency, and reliability
of the different systems.

The highest diaphragm pump hydraulic efficiency measured was 48%, and the
highest helical pump hydraulic efficiency measured was 60%. The peak total
system efficiency (e.g. solar radiation to pumped water) measured for the
diaphragm and helical pumps were5% and7%, respectively (based on PV modules
with 12% efficiency). The daily water volume of the three-chamber high head
diaphragm pump performed better than the dual-chamber high head diaphragm
pump (5 to 100% depending on PV array input power and pumping depth). Use of
a controller was shown to improve the quad diaphragm pump performance below
a solar irradiance of 600 W/m2(20 m head) to 800 W/m2(30 m head). While
diaphragm pumps made mostly of plastic demonstrated similar to much better
pumping performance than diaphragm pumps made with a high proportion of
metal, the metal pumps demonstrated a longer service life (>2 years) than the
plastic pumps service life​ .

10
 CHAPTER-3
​

DESIGN AND EXPERIMENTATION

3.1 WORKING PRINCIPLE

Reciprocating pump is a positive displacement pump, which causes a fluid to move by

trapping a Fixed amount of it then displacing that trapped volume into the discharge
pipe. The fluid enters a Pumping chamber via an inlet valve and is pushed out via
outlet valve by the action of the piston or diaphragm. They are either single acting;
independent suction and discharge strokes or Double acting; suction and discharge in
both directions​.

11
 FIG:- 3.1 ( RECIPROCATING PUMP WORKING PRINCIPLE)

During the suction stroke the piston moves left thus creating vacuum in the Cylinder.
This vacuum causes the suction valve to open and water enters the Cylinder.
During the delivery stroke the piston moves towards right. This increasing
pressure in the cylinder causes the suction valve to close and delivery to open and
water is forced in the delivery pipe

. The air vessel is used to get uniform discharge. Reciprocating pumps are
self-priming and are suitable for very high heads at low flows. They deliver
reliable discharge flows and is often used for metering duties because of
constancy of flow rate. ​The piston connected to the connecting rod will move in
linear direction. If crank moves outwards then the piston moves towards its right
and create vacuum in the cylinder. The flow rate is changed only by adjusting the
rpm of the driver. These pumps deliver a highly pulsed flow.

If a smooth flow is required then the discharge flow system has to include
additional features such as accumulators. An automatic relief valve set at a safe
pressure is used on the discharge side of all positive displacement pumps. The
performance of a pump is characterized by its net head h, which is defined as the
change in Bernoulli head between the suction side and the delivery side of the
pump. H is expressed in equivalent column height of water.

Generally the above process can be observed in a single acting reciprocating

pump where there is only one delivery stroke per one revolution of crank. But
when it comes to double acting reciprocating pump, there will be two delivery
strokes per one revolution of crank.

12
3.2 COMPONENTS

There are several components in a solar reciprocating pump. Each and every

​
components are crucial for the machine. Reciprocating pump is a positive

displacement pump where certain volume of liquid is collected in enclosed volume

and is discharged using pressure to the required application. Reciprocating pumps are
more suitable for low volumes of flow at high pressures . The main components of
the solar reciprocating pump is given below.

● 10W ,12V SOLAR PANEL

● 12V BATTERY
● 12V DC MOTOR
● CONNECTING ROD
● CIRCULAR DISC
● SUCTION PIPE
● DELIVERY PIPE
● CONTROL SWITCH
● WIRE
● BASE FRAME
● VALVES
● CONTRL SWITCH

13
● SUCTION AND DELIVERY TANKS

14
3.3 COMPONENT SPECIFICATION

3.3.1 SOLAR PANEL

Solar panels work by absorbing sunlight with photovoltaic cells, generating direct
current (DC) energy and then converting it to usable alternating current
(AC) energy with the help of inverter technology. AC energy then flows through the
home's electrical panel and is distributed accordingly.

​When photons hit a solar cell, they knock electrons loose from their atoms. If
conductors are attached to the positive and negative sides of a cell, it forms an
electrical circuit. When electrons flow through such a circuit, they generate electricity.
Multiple cells make up a solar panel, and multiple panels (modules) can be wired
together to form a solar array. The more panels you can deploy, the more energy you
can expect to generate.

​Photovoltaic (PV) solar panels are made up of many solar cells. Solar cells are
made of silicon, like semiconductors. They are constructed with a positive layer and a
negative layer, which together create an electric field, just like in a battery.
PV electrons move from the negative side of the battery, through the lamp, and
return to the positive side of the battery. Solar panels generate direct current (DC)
electricity. With DC electricity, electrons flow in one direction around a circuit. This
example shows a battery powering a light bulb. The

With AC (alternating current) electricity, electrons are pushed and pulled,

periodically reversing direction, much like the cylinder of a car’s engine. Generators
create AC electricity when a coil of wire is spun next to a magnet. Many different
energy sources can “turn the handle” of this generator, such as gas or diesel fuel,
hydroelectricity, nuclear, coal, wind, or solar.

15
AC electricity was chosen for the U.S. electrical power grid, primarily because it is
less expensive to transmit over long distances. However, solar panels create DC
electricity. How do we get DC electricity into the AC grid? We use an inverter.

FIG 3.2 ( SOLAR PANEL)

The specification of the solar panel is given below

● Relatedpower;10w
● Voc:20.6V
● Vop:17.3V
● Short circuit current (Isc):0.69A
● Working current(Iop):0.58A
● Output Tolerance:±3%

16
 ● temperature range :- -40 degree c to +80 degree C
● battery voltage :- 12v
● glass thickness :- 3.2 mm

3.3.2 BATTERY

Solar batteries work by converting the DC energy ​being produced by your solar
panels and storing it as AC power for later use... When you install a solar battery as
part of your solar panel system, you are able to store excess solar electricity at your
home instead of sending it back to the grid.

Batteries used in home energy storage typically are made with one of three
chemical compositions: lead acid, lithium ion, and saltwater. In most cases, lithium
ion batteries are the best option for a solar panel system, though other battery
types can be more affordable.

PV electrons move from the negative side of the battery, through the lamp, and
return to the positive side of the battery.solar panels generate direct current (DC)
electricity. With DC electricity, electrons flow in one direction around a circuit. This
example shows a battery powering a light bulb. The

17
 FIG 3.3 (BATTERY)

It will take 4 hours to charge a 12V battery with a 10W solar panel depending on how
much sun time it has. You must use a charge controller which ensures that
the battery isn't overcharged.

3.3.3 DC MOTOR

​Construction of a DC motor is same as that of a DCgenerator. A motor is an electrical

machine which converts electrical energy into mechanical energy. The principle of
working of a DC motor is that "whenever a current carrying conductor is placed in a
magnetic field, it experiences a mechanical force.

18
 FIG 3.3 (DC MOTOR)

1 RATED VOLATGE 12V

2 RATED CURRENT 7A

3 RATED SPEED 35 RPM

4 NOISE < 55db

Table no :3- 1 ( motor specification )

19
3.3.4 PISTON CYLINDER

Piston pumps can pump at a constant flow rate against any kind of discharge pressure.
Both Piston pumps and Plunger pumps are reciprocating positive displacement
pumps that use a plunger orpiston to move fluid/substance through a cylindrical
lchamber.

​Reciprocating pumps operate by drawing liquid into a chamber or cylinder by

the action of a piston, a plunger or a diaphragm; the liquid is then discharged in the
required direction by the use of check valves. ... At the same time, the higher
discharge-line pressure holds the discharge valve closed.

In this project a pneumatic cylinder is being used in specific dimension.

20
 DIAGRAM 3.5 ( PISTON CYLINDER)

In the table the specification of the piston cylinder is given.

1 TYPE SINGLE ACTING RECIPROCATING

PUMP

82 DIAMETER( d) 25mm

3 STROKE (L) 125mm

4 HEAD 7m

5 MECHANICAL EFFICIENCY 50%

6 BORE DIA 50mm

Table nio 3.2 ( piston cylinder specification)

3.3.5SUCTION AND DELIVERY PIPES

21
Suction pipe connects the source of liquid to the cylinder of the reciprocating pump.
The liquid is suck by this pipe from the source to the cylinder Delivery pipe connects
cylinder of pump to the outlet source. The liquid is delivered to desired outlet location
through this pipe.

Suction valve is non-return valve which means only one directional flow is possible in
this type of valve. This is placed between suction pipe inlet and cylinder. During
suction of liquid it is opened and during discharge it is closed.

DIAGRAM 3.6 (PIPES) DIAGRAM3.7 (CONNECTOR)

Pipe external diameter – 8mm

Pipe internal diameter – 6mm

3.3.6 CIRCULAR DISC

The circular is used to convert the circular motion into reciprocating motion for the
movement of the piston in the cylinder .The circular disc is made up of cast iron .The
specification is mentioned in the table.

22
 DIAGRAM 3.8 ( CIRCULAR DISC)

1 DIA 124mm

2 THICKNESS 4mm

3 INTERNAL HOLE DIA 6mm

23
 TABLE 3.3 ( SPECIFICATION OF DISC)

3.3.7CONNECTING ROD

The connecting rod is the connection between the circular disc and the piston. The
connecting rod is made of cast iron. It has two connection point at the both ends. The
connecting rod coverts the circular motion produced by the disc into reciprocating
motion.

The connection rod must be of a certain weight because it has an effect on the motion.
It if the rod is light, then the engine will be able to move faster and accelerate more
quickly. But weight is not the only important thing; the connection rod must be light
and strong at the same time. It should be strong enough to resist all forces produced
by the engine, as well as the powerful force that the piston creates when it is moving
to the dead center. If the connection rod is weak, that force made by the piston can
break it in half or pull it out from its place.​ The specification is given below.

GIAGRAM 3.9(CONNECTING ROD)

LENGTH 160mm

THICKNESS 4mm

24
 HOLE DIA 6mm
Table 3.4 ( connecting rod specification)

3.3.8 SWITCH & WIRE

A switch gate is connected between the battery and the motor to operate
at a perfect timing. The switch is connected between the wire used in the equipment is
3​ mm diameter.

DIAGRAM 3.10 (SWITCH & WIRE)

3.3.9 BASE FRAME

Structural frame bases are used to support mechanical equipment and

provide rigid platforms for attachment of vibration isolators, without allowing

​ rames are
excessive differential movement between driving and driven members. F

structural members responsible to bear weight , be stiff and control vibrations at the

25
very basic level​. Proper foundation of pumps mounting reduces vibration levels,

which in turn leads to a significant increase in Mean Time Between Failures (MTBF),
extended lifetime of mechanical seals and bearings and consequently reduced total life
cycle Cost.

26
Fig 3.11 ( base frame)

27
 ​CHAPTER-4

FABRICATION

4.1 BASE FRAME

● For preparing the base for the reciprocating pump iron rods are required. The
iron rods are collected.
● The rods are taken to the cutting machine for cutting purpose.
● 4 base supporting beams are cut by the cutting machine of the length of 42
centimeter.
● 6 side beams are cut by the length of 30 centimeter.
● 2 beams of 20 cm, 2 beams of 40cm, 2 beams of 10 cm are cut as per the
required dimensions.

28
 IMAGE 4.1 ( CUTTING)

● The base rods are ready for assembling purpose. The beams will be assembled
by welding process.
● The arc welding process is suitable for the assembly.
● The specimen are properly welded by the arc welding process.
● The strength is checked of the base material.
● Water is sprayed on the base for cooling purpose.

IMAGE 4.2 ( WELDING)

DIFFICULTIES & HANDLING

● While cutting the rods there was the dimension error. The cutting material
became waste and a new rod is cut with proper dimension and without any
error.
● While cutting the cutter wheel broke and the new wheel was fitted to the
cutting machine.
● At the time of welding the electrode holder was loose so it was tightened and
prepared for the next use.

29
 ● At the initial stage the welding was not strong enough. So the component was
again welded for strength purpose.

IMAGE 4.3 ( BASE MATERIAL)

4.2CONNECTING ROD
● An iron rod of thickness 4mm and length of 16cm is cut by the cutting
machine.
● 2bearings are selected for connecting purpose.
● 2 bearings are joined at both the ends of connecting rod.
● The bearings are connected by the arc welding process.
● The connecting rod is made straight be tapping with hammer.

30
 IMAGE 4.4 ( MAKING OF CONNECTING ROD)

4.3 CIRCULAR DISC

● A 4mm thick grey cast iron plate is selected.
● A thin line of 6.2cm radius is drawn on the plate with pencil.
● With the given dimension the disc is cut by the machine.
● The surface of the disc is finished with surface grinding machine with
proper dimension.
● A hole of 6mm diameter is made by the drilling machine in the centre
of the circular disc.
● Again the centre part of the disc is finished by the surface grinding
machine.
● The disc is measured for the motor as it is perfect or not.

31
 IMAGE 4.5 ( MAKING OF CIRCULAR DISC)

DIFFICULTIES AND HANDLING

● While cutting the circular disc there was little bit roughness. The surface was
finished by the grinding machine.
● The hole drilled on the circular disc was having some dimension error so the
error was overcome by littlebit futher drilling.

4.4 FINAL ASSEMBLING

● The solar panel is placed on the base frame.

● The wire is connected from the solar panel to the battery.
● The battery is placed on the base frame.

32
 IMAGE 4.6 ( CONNECTION WITH SOLAR PANEL)

● The cylinder is placed on the frame .

● The cylinder is tightened by the metal binder.
● A bolt is connected at the end of the piston rod by the welding process.

33
 IMAGE 4.7 ( CONNECTION OF PISTON CYLINDER)

● The circular disc is connected with the motor by welding process.

● A bolt is connected on the circular disc by welding process.
● A measurement of the piston rod is taken.
● The connecting rod is joined between the piston rod end and the circular disc
where the bolts are fitted.
● The connecting rod is tightened by fitting nuts on the bolts.
● The motor is placed on the base with the proper distance as per the required
measurement.

34
 IMAGE 4.8( MOTOR WITH DISC)

● The suction and delivery pipes are cut as per the required size.
● A connector is joined with the cylinder where the ports are present.
● The suction pipe and the delivery pipes are joined with the connector.
● 2 tanks are placed near the base frame.
● One tank is suction tank and another tank is the delivery tank.
● The suction pipe is dipped in the suction pipe.
● The delivery pipe is dipped in the delivery tank.`

35
 IMAGE 4.9( CONNECTION OF PIPES)

● The motor is connected with the solar battery with wire.

● The battery is connected with the solar panel by the wire.
● An operating switch is connected between the motor and the battery for on and
off purpose.
● The testing of the total reciprocating pump is done after the full charge of the
battery by the solar panel.

DIFFICULTIES AND HANDLING

● When the connecting rod was joined between the disc and piston rod, it was
seemed to be bend. So it was made straight by hammering.
● When the motor was fitted on the base it was loose so it was tightened by the
iron binder.
● The battery was not stable due to vibration of the motor and pump. So an extra
rod was welded at the place of battery and the battery was placed in a stable
condition.

36
IAMGE 4.10 ( SOLAR RECIPROCATING PUMP)

37
 ​ CHAPTER-5

TESTING AND CALCULATIONS

5.1TESTING

After fabrication of the total reciprocating pump it was ready for testing. The charge
storage was quite low. So the solar panel and the battery was kept in sunlight for 5-6
hours for charging purpose.

After the full charge again it was connected as previous position. The suction
tank was filled with water and the suction pipe was dipped into it. The delivery pipe
was dipped into the delivery tank.

The switch was on , the motor started rotating but it failed to suck the water from
the suction tank because of the air leakage. So the air leakage was stopped by
tightening the pipes with the pipe connector.

The pump started sucking from the suction tank but at the delivery time the water
was coming out from both the ends of the connector. So one end was sealed by the
glue .It was sealed permanently.

While the motor was rotating we noticed that the motor was unstable due to the
vibration so the vibration was reduced by tightening the motor with the base.

The pump was on up to 10 minutes. In that time we took the readings of the rotation
of the disc, discharge of water per minute etc. Then as per the data the results for
toque, discharge, efficiency had been calculated and it is given below.

The theoretical discharge was compared with the practical discharge value and the
power consumption was also calculated.

38
5.2 CALCULATIONS

Losses Ignored

Bore Diameter= 50mm

Length of stroke= 125mm

Head or height h=0.5m

Speed of rotation N=15rpm

Pipe Diameter= 6mm

Pipe Length=1m

Suction lift= 0.25m

5.2.1DISCHARGE

Q = π×d2 ×L×N/(4×60)

= π×(0.05)2 ×0.125×35/(4×60)

= 14.30×10-5 m 3 /s

5.2.2 PRESSSURE AND SPEED

P = ρ×g×h

= 1000×9.81×.5

= 4905 Pa

Max speed (piston) = ɷ×r

= 2×π×N×r/60

39
= 2× π×35×0.062/60

=0.227m/s

Max velocity of water in delivery pipe

= 0.097×0.052/ 0.0092

=2.16m/s

5.2.3 POWER

.Power Required for motor ​:- V×I

Where , P = Power in Watt

V = voltage of battery in Volt

I = Current of battery in Ampere

P = 12×7 P

= 84 W

Power​ can be also given by :-

P = 2πNT/60 Where ,

N = motor speed in rpm

T = Torque of motor in N-m

2π × 35 × T /60

=84

40
Torque provided by motor is,

T= 22.92N-m

41
Radius of flywheel in meter R = 0.062 m

Width of flywheel in meter b = 0.004 m

Mass of solid disk​ flywheel is given by m =πR​2​bρ

But , ρ = 7800 Kg/m​3​ for Gray Cast Iron

m = π × 0.062​2​ × 0.004 × 7800 m

= 0.376 Kg.

5.2.4 TORQUE

​Torque produced by flywheel

T = F. r T

= (m × a) × r

= 0.376 × 9.81 × 0.062

=0.228N-m

5.2.5 DISCHARGE AND EFFICIENCY

Discharge of pump per second

= Discharge in one revolution× No. of revolution per second

Q ୦ = A. L. n/ 60 Where ,

A = area of pump in m​2

L = stroke of pump in meter

n = No. of strokes per minute = 35 rpm.

Q ୦ = Theoretical discharge of pump in m3​/s

42
A = π/ 4 ×d​2

= π/ 4 ×0.006​2

= 2.82×10​--5​ m​2

Theoretical discharge

Q ୦ =( .0125×2.82×10-5​×35)/60

=0.002×10​-5​m​3​/s

Q ୦ = 0.02×10-5​×1000

=20×10​-5​ lit/sec

Q ୦ = 20×10-5​×60

=12×10​-3​m​3​/’h

Actual discharge is 4×10​-3​m​3​/h

Volumetric efficiency= ( actual discharge/theoretical discharge)×100

Efficiency=(4×10​-3​/12×10​-3​)×100

=33.3%

43
44
In order to charge the 12V , 7A battery , various solar panels having different power
range is available

Capacity Time Required For Charging (hours)

For 6 W 6 hrs

For 10 W 4 hrs

For 14 W 2.5 hrs

TABLE NO 5.1 ( PANEL CHARGING TIME)

Hence , It will be advisable to use 10 W solar panel which can fully charge the 12 V,
7A battery in 4 hours. As total discharging will be occurred in 3.5 hrs.

45
5.3 COST ESTIMATION

5.3.1COST OF MATERIAL

​PART MATERIAL ​RATE/KG ​TOTAL

WEIGHT(KG) RATE

CIRCULAR
DISC GREY CAST 0.3 35 11
IRON
CONNECTING
ROD GREY CAST 0.2 35 7
IRON
BASE
LINK C-45 4 45 180

CONTAINER
BASE C-45 3 45 135

TOTAL-333RUPEES

​TABLE 5.2 ( COST OF MATERIALS)

5.3.2 MACHINNING COST

MACHINNING ​TIME(MIN) ​COST/HR ​COST

CUTTING 30 ​ 300 150

DRILLING 10 250 40

GRINDING 15 200 50

WELDING
150 400 1000
TOTAL MACHINNING COST= 1240 RUPEES

46
TABLE 5.3 ( MACHINNING COST)

47
5.3.3 COST OF STANDARD PARTS

PART QUANTITY PRICE TOTAL

PRICE

SOLAR PANEL 1 1500 1500

CYLINDER 1 900 900

PIPES 2MTR 80/mtr 160

CONNECTOR 1 40 40

BATTERY 1 1600 1600

MOTOR 1 1100 1100

WIRE 3MTR 10 30

NUT AND BOLT 2 10 20

SWITCH 1 10 10
TOTAL PARTS COST=5360

TABLE 5.4 ( STANDARD PART COST)

Total project cost= material cost + machining cost + standard parts cost

= 1240+ 333 + 5360

= 6933 rupees

48
 ​CHAPTER-6

SCOPE& APPLICATION
6.1 APPLICATION OF RECIPROCATING PUMP

● Reciprocating pumps are positive displacement pumps, where they displace

the fluid particles at high pressures.
● Usually they are used in high pressure requirement applications where
pressure is a priority compared to quantity.
● Reciprocating pumps are used in all injection based applications, such as: fuel
injection in engines, medicine industry applications, and some water pumping
applications.
● It is used at a place where low discharge rate is required with high pressure. It
is mostly used to deliver water at large heights such as in deep well.
● It is used for inflation of tires of bicycles.

● In oil and gas industries.

● petrochemical and refinery industries.
● As a feed water pump in boiler because high pressure water is required.
● Hilly areas and also in agriculture .
● Reciprocating pumps are used majorly In boiler water feeds as water needs to
be feed at high pressure and we can't use centrifugal pumps due to cavitations’
problem.
● Some of the drip irrigation system also uses reciprocating pumps.
●

49
6.2ADVANTAGES

● Solar-powered Water Systems are practical in flat terrain where the sun
shines.
● Solar-powered water pumps can be placed in or next to the pond or other
source of water and the water can be pumped where it is needed.
● Solar water pumping is clean and efficient.
● Solar electric water pumping cuts down on waste because it’s based on
natural cycles. Your panels give the most pumping power on the sunniest
days---when you need the most water.
● Solar power is clean. You never have to worry about polluting the
groundwater or air with a gas-powered pump.
● Solar-powered water systems take very little maintenance because they only
have a few moving parts.
● They have long life---usually 20 to 40 years. And solar water systems never
run out of fuel as long as the sun is shining
● power required for driving the motor is small. So it is energy efficient.
● It is cost efficient. As the total cost of the project is 6933 Rs. So, it is cost
efficient.
● It does not require any electricity because the battery is charge by solar panel.
● It is eco friendly:- It uses solar energy for charging the battery. So it does not
create any pollution. Hence it is eco friendly.
● It can be used in rural & tribal areas for pumping the water, where the
electricity is not available or problem of load shading is major.
● Mechanism is simple & easy to understand.

50
 ● To pump the water. It requires less force and operation is simple.
● No human energy rather than pushing the pendulum with hand is required.
● No fatigue to the operator.

6.3 DISADVANTAGE

● Relatively high initial cost.

● Lower output in cloudy weather.
● Power loss is more comparison to electrical pumps.
● Instant current cannot be produced by solar panel.

6.4 PROBLEM IDENTIFICATION

Mostly, the batteries utilized as a part of framework have a low life time,
about two years, which is to a great degree low contrasted with the helpful
existence of 20 years of a PV module. Also, installation and upkeep of such
frameworks make the expense considerably high. Besides, if there should arise an
occurrence of crisis the absence of battery swap is in charge of the disappointment
of such frameworks in separated ranges. The large portion of business frameworks
utilize low voltage dc motors, consequently keeping away from a support stage
between the PV module and the motor.

Unfortunately, dc motors have lesser effectiveness and highest

upkeep prize contrasted with affectation motors and are not best choice for
applications in detached zones, where there is no master staff for working and
keeping up these motors. Another issue is that low-voltage dc motors are not
standard things in the nearby markets. We can supplant these motors by
Permanent Magnet DC motor or (PMSM) however these are minimal
unreasonable. While contemplating converter topology it is found that the
majority of framework comprise of isolated voltage-fed converters which have a
high input current ripple, it forces to utilize extensive data filter capacitors in
framework & regularly they are electrolytic, which have a little lifetime , it
straightforwardly influence general life time of converter.

51
 Also voltage-fed converters have inherent step-down
characteristic, for this huge transformer turns proportion expected to support the
output voltage, the high output diode voltage stress, and the interest of a LC
output filter make it to fee I that as second decision for this application.
Comparatively, current-fed converters have some advantage.

As they have an inductor at the input, which has

tendency to have data current ripple as low as required, in this manner precluding
the need of the input capacitor at the board voltage, they are picked up from the
boost converter, having a basic high step-up voltage ratio, which dispose of the
required transformer turns ratio. To ensure the maximum utilization of the
available energy dc/dc converter with a higher voltage transformation ratio is
suggested. It is due to the low-voltage property of the PV panels and small input
current ripple so that it does not oscillate over the maximum power point (MPP)
of the PV module.

6.5 KEY ASPECTS AND SCOPE OF SOLAR PUMP

In general, the investment required for a PV pumping system is Rs

250-300/Wp (where Rs is the Indian rupee and Wp is watts peak). For example, the
cost of a 900 Wp unit would be Rs 225,000-270,000, but with subsidies, this will be
reduced to Rs 50,000. To make the best use of solar energy, the PV system, the
groundwater pump and the water distribution system have to be well matched. The
PV power provided must cover the power demand of the pump adequately. This is
determined by the relationship between the required discharge flow, the total head and
the pump efficiency.
This depends on the type of pump, which in turn depends
on the depth of the available water source. Although positive displacement pumps are
preferred for large heads, centrifugal pumps are most commonly used. Photovoltaic
(PV) panel electrical outputs are rated according to industry Standard Test Conditions
(STC) of 1000 W m-2 incident solar radiation at an operating cell temperature of

52
25oC and under an absolute air mass of 1.5. Environmental conditions met outside the
laboratory will cause a decrease in PV performance from the STC rating, the
magnitude of which depends on the module technology. Many additional losses are
incurred due to the inefficiencies in transferring energy from the PV panels to a load,
such as a pump or battery bank, thus resulting in a secondary decline of performance.
Though there have been studies measuring outdoor performance of PV modules, there
is a great need for further field studies of complete PV systems.

Another important aspect would be the ability to model the potential solar radiation,
PV power output, and subsequent water output for the purpose of irrigation
scheduling. Photovoltaic powered water pumping systems (photo irrigation) have
been studied by researchers in many years. Studies mostly concentrated on DC motors
cause of energy obtained from solar panel is DC (Lawrance et al., 1995, Dorsum et
al., 2005). These are shown that better results were obtained for performance analysis
(Kolhe et al., 2004., Kolhe et al., 2000). Photo-irrigation system has advantages than
flooding irrigation. Some of these are, bringing utilization of water sources more
efficient, preventing erosion and growing of weeds only by irrigating the requested
areas (Cuadros et al., 2004), decreasing moisture stress (Pande, et al., 2003), no
operation cost, providing opportunity for local energy sources and exhibiting a
parallel point of view with water requirement (Ghoneim 2006).

The advantages of using wireless sensor is to reduce wiring and piping costs,
and easier to install and maintenance especially large areas (Dursun et al., 2010).
Energy of pumps used for the agricultural irrigation is generally provided from
electrical energy or fossil fuels. Since fossil fuels commence to annihilate besides its
increasing of prices and hazards to environment alternative energy seeking efforts has
become inevitable also in agricultural sector. Solar energy that is sensitive to
environment, clean and requiring no maintenance is an alternative renewable energy
source especially for countries like Turkey having a high amount of annual solar
irradiation rate. When it is considered by means of requirement for irrigation the
advantage of PV pumping systems is that water demand and increasing for sun

53
shining are compatible characteristically (Anis et al., 1994). In summer months
obtained solar energy increases and also naturally water requirement of trees
increases.

The cost of solar PV has come down and cost of diesel has been regularly increasing.
At present the cost of solar PV is very much less to diesel, solar PV cost shall be half
of diesel within three to four years, since approaching towards grid parity. 400,000
telecom towers are associated with diesel generating sets having capacity 3 to 5 KW.
60% Telecom towers located in urban and semi urban areas and 100% located in the
villages are run by diesel generating sets. Recently in 2013, Maurya V.N. et al [35]
focused their attention to capital cost modeling. In fact, off-grid potential is unlimited
in India and is about 20 to 25% potential of the world (Arora 2014). Solar water
pumps are often thought of as being an expensive technology, which is not able to
pump enough water and which is not durable. However, solar water pumps have come
a long way in 25 years and today there are solar pumps on the market which have
improved on previous technology, e.g.: Submersible pumps which can pump up to
200m heads; Pumps that are able to pump larger volumes of water, e.g.: At 100m,
about 10,000 liters per day; At 50m, about 20,000 liters per day; Above performance
can be doubled through dual systems (if the borehole allows this).

Low maintenance requirements (3 to 5 years); Good

performance which means fewer solar panels to pump the same amount of water;
Some of the pump models can be backed-up by a genets to pump additional water
with the same pump during the night or during overcast days;

Good quality and reliability Simple to install Furthermore, solar pumps are well
known for having the following features: Require minimal attention as they are
self-starting; Solar pumps are “good” for boreholes as they pump over the whole day;
Weak boreholes can be used effectively with a low volume pump due to pumping 8 to
10 hours a day; In most cases, a solar pump offers an ideal solution to the diesel
option which requires operating funds (with uncertainty about future diesel prices),
time investment for operating pump (manual starting etc.) and logistics for fuel,
maintenance, installation and de-installation.

54
55
 ​FUTURE EXTENSION

● The project solar reciprocating pump is a

prototype version of the actual pump. There can be several
modifications in this project. The discharge of this reciprocating
pump is quite low. In future The discharge can be increased by
applying other methods.
● The DC motor used in this project is a low voltage and torque
motor. For more voltage and torque the cost will be high. In Future
there will be high voltage and torque DC motor in low price range
so the reciprocating pump power will be increased and there will be
more discharge.
● In future the high discharge pump can be made by
using high voltage and high current solar panel. The high discharge
pump can be used in industries like dairy farms and plastic injection
moulding industries
● The discharge rate of the reciprocating pump is 4ltrs/hour .
The future plan for this project is it will discharge more the
1000litres/hr. It can be done by using high capacity motor, solar
panel, and high volume piston cylinder.

56
 CHAPTER-7
​

CONCLUSION AND REFERENCE

7.1CONCLUSION
The method used here to build solar powered water pumping system is cost effective
comparatively to an electrically operated hydraulic pump. Since here
non-conventional energy is used to achieve the required head. Discharge obtained
from the observations is 2.5liters per minute. The reciprocating pump built by us is
built with the help of simple and easily available materials still we have successful to
demonstrate the worth of a reciprocating pump. This device serves its purpose to
some extent, but with proper course of actions, it can perform still better.

Under these circumstances of inadequate supply of

electrical energy, the solar water pump can play a significant role. Though the
upfront cost of the solar pumping systems potentially hinder to popularize the systems
in rural areas but private companies, bank, development organizations and
government can provide loan, subsidy or other suitable options so that it can be
widely used in rural areas. The proposed solar water pumping system has long
lifetime and it is maintenance free. Together with decreasing PV module costs and
increasing efficiency, PV is getting more pervasive than ever.

57
7.2 REFERENCES

1. Prof. R.S. Khurmi, J.K. Gupta; Theory of Machines; Eurasia publishing house
pvt.Ltd.2006 2nd Edition

2. Prof. Ramamurathan; Fluid mechanism and machines; Dhanpat Rai and sons
publication

3. Prof. V.B. Bhandari;Machine Design; Tata McGraw Hill Publishing Co. New Delhi

4. Dr. R. K. Bansal; Fluid Mechanics and Hydraulics machines;Laxmi Publication 9th

Edition

5.PSG Design Data Book .

6.Prof.R.B.Patil; Dynamics of machinery; Techmax Publication 3rd Edition

7.F. P. Beer & E. R. Johnson; Engineering Mechanics - Space Forces, Mechanics for
engineers, Statics; McGraw Hill Publications 4th Edition

8. S.P.Sukhatme ; Solar Energy – Principles of Thermal collection and storage.

9. report-on-reciprocating-pump.pdf

WEBSITES

1.www.Wikipedia.org

2. www.google.com

3. ​www.pumpindia.com

4. www.irjet.net

58
59
60
61
62
63