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THE$ROSTATIC

·SPI'RAL

PUMP

DESIGN, CONSTRUCTION

AND':FIELD TESTS

'OF LOCALlY-DEVELOPED

SPlRAL PUMPS

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JASPERS VERLAG

Price: $10,-/DM 18,­

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H Y D R o S T A TIC

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A FARMING SYSTEMS COMPONENT FOR THE

IRRIGATION OF DIVERSIFIED CROPS

D E S I G N.

e o N S T R U e T ION

and F I E L D - T E S T S

Ludwig c.A. Naegel

JASPERS VERLAG MUNICH/GERMANY

c.A. N aeget studied biology and chemistry at the University of the University of Hannover his doctorate in Natural Sciences. After postdoctoral studíes in Constance, london, and Sto louis, Mo. U.S.A. returned to Germany and worked in intensive warmwater fish culture. He conti­ nued teaching and reearch in aquaculture in Costa Rica before accepting a position in the Philippines where he worked for nearly eight years as associate professor in Clquaculture and farming systems, and for two years as a research fellow at the Agricultural Engineering Division of the International Rice Research Institute (IRRI). At present he works as senior scientist with CIBNOR in la Paz, Baja California Sur, México. His maln professional interests are in developing integrated agricultural far­ ming systems, which are economically, ecologically safe, and socially just for an cient and sustainable utilization of limited land, water and energy resources.

© 1998 by Jaspers Verlag Munich, Josephsplatz 5 D-80798 München Types: Futura Book,light und Bold. QuarkXPress Printed: Printex, Verona-Italy

5

CONTENTS THE STREAM-DRIVEN SPIRAL PUMP: A FARMING SYSTEMS COMPONENT FOR THE IRRIGATION OF DIVERSIFIED CROPS.

1. The stream-driven spiral pump: a farming systems component for the

9

9

irrigation of diversified crops. A. Abstract B. Introduction. C. The reinvention of the hydrostatic spiral pump. D. The working principie of the spiral pump.

10 11

12

11. laboratory tests to determine efficiencies under different working con­

ditions. A. Materials and methods. B. Laboratory tests of spiral pumps C. Results. 111. Determination of the flow and height to which water has to be pum­

pedo Power requirements to drive a spiral pump. A. Hydropower. B. Alternative power sources to drive the spiral pump during

times of low sfream flow. 1. Human power. 2. Animal power. V. Alternative water-lifting devices that use hydropower to deliver water

to a higher head than the pump structure itself. A. The coil pump. B. The hydraulic ram pump. C. Turbine pumps. VI. Guidelines for prediction of the delivered water volume pump at a given flow to a given head.

6

13

13

14

16

VII. Field tests of spiral pumps under actual field conditions in Abra,

Northern Philippines. A. Abstract B. Introduction C. Material and Methods D. Results

43

43

VIII. Remarks about the use of different materials for the construction of a

spiral pump.

50

IX. Farming systems and related aspects in use of the spiral pump. A. Abstract B. Introduction C. Farming systems in Abra. D. Questions of crop diversification. E. Irrigation and salinization. F. Charging of fees for water delivered with the spiral pump. G. Economics of the spiral pump. H. Marketing strategies for the spiral pump. X.

21

25

25

28

28

32

Advantages and disadvantages of the spiral pump. A. Advantages. B. Disadvantages.

41

41

41

51

51

51

53

54

56

57

58

60

61

61

62

XI. Conclusions.

63

XII. References.

63

XIII. Acknowledgements.

66

XIV. Appendix: Technical drawings of the spiral pump.

67

32

32

33

33

a spiral

34

7

l. THE STREAM-DRIVEN SPIRAL PUMP: A FARMING SYSTEMS COMPONENT FOR THE IRRIGATION OF DIVERSIFIED CROPS A. ABSTRAeT Rainfed cultivation dominates the agricultural sector in most developing countries. Among farmers engaged in rainfed agriculture, poverty is widespread. availability of water is a major constraint for increased agricultural productivity. Many marginal farmers cannot irrigate their fields, even in areas where there are· uither existing irrigation systems or streams that could be tapped, because their lields are situated aboye the water level. The use of motor-powered pumps for irri­ ¡lation is too costly. The search for pumps driven by renewable energy sources nnd built out of available materials by local craftsmen is therefore a high research priority among agricultural engineers. Among the nonconventional means lo harn­ oss the kinetic energy of streams for pumping water is the stream-driven spiral pump. Until now only limited information has been available about the design variables for most efficient operations. Researchers have constructed laboratory prototypes for trials. Each prototype had an outer diameter of 2.0 m and were made out of flexible tuóe materials of different inner diameters. Varying the speed (Jf rotation of the pump, the water volume scooped into the tube, the sum of coil diameters, and the height of water delivery affecled the volume of delivered water and energy required. By setting the output of the pump in relation to the required energy, efficiency data were obtained for different variables. Through a multiple and nonlinear regression analysis, highly significant formulae were derived for performance predictions of pump operation, under varying conditions. With Ihe data obtained and with information on the kinetic energy of a given stream and the drag coefficient of the paddles of the pump, it is now possible to match design factors to field conditions. This allows the most efficient energy use of a given stra­ am flow for pumping purposes. To verify the laboratory results and to determine the acceptance of the new technology by small-scale farmers, field tests with spiral pumps of different designs were made at Bangued, in the Province of Abra, Philippines. The performance data of the tested spiral pumps were found to agree closely with the results from the laboratory tests. No major problems occurred durlng testing. The spiral pump has come to be considered by the farmers as a HGIFt from God".

8

9

B. INTRODUCTlON

who own less than 5 ha of land. In generál, the land and water management on Ihese small-scale farms is better than on larger units. This is achieved by using more labour per hedare than on larger farms. Additionally, small-seale farms (lchieve better energy ratios than large ones; they produce a mueh higher ealorie value than the energy input to grow the food. In many countries, such as the Philippines, the most suitable areas for gravi­ Iy irrigation have already beentapped. Petroleum-based fuels and electricily to run pumps for large-seale irrigation systems are getting more expensive. Thus a growth in food production can be achieved by improving the produdivily of small-scale lInd labour-intensive farms. This is where spiral pumps have the greatest potential

Feeding the rapidly growing world population is an inereasingly vital ehal­ lenge. There is today no other readily identifiable yield-inereasing teehnology at hand than an improved seed-water-fertilizer approaeh (Fraenkel, 1986). Beeause there is less and less available fertile land, vertical development is the logieal alter­ native to inerease the production from existing agricultural land. By using more labour per hectare compared with large farms, most land in developing countries under relatively intensive food produdion is in small farms (Berry and Cline, 1979; Pesek, 1981; Fraenkel, 1986). The majorily of farmers in developing countries own less than 5 hectares of arable land; in Asia, even less than 1 hedare. Potential harvest increases could be significant if even small yield increments could Cost-effedive pumps are needed to irrigate the fields situated aboye canals be aehieved at these farms. Improvement and provision of water for the irrigation (lnd streams. Gravily irrigation systems are useless for these fields. The studies of crops is the best way to bring idle and underüsed lands under cultivation during described here are centered on anirrigation teehnology that can (a) be powered the whole year, and not just during the rainy season. Without irrigation, high-qual a renewable energy source, (b) pump water to a higher head than the pump Iy seeds and fertilizers are useless. Through irrigation, unused land can be broug ~trueture itself, (e) be built out of inexpensive available materials, (d) is simple under cultivation, and crop yields improved three - to four-fold over rainfed agricul­ onough to be repaired by local craftsmen, and e) be easily assembled and disas­ ture. Irrigation allows greater farming intensily, and produces improved economic sembled. securily to the farmer by reducing the drought risk. This allows the use of high-viAIa. seeds, inereased fertilizer application, mechanization, and control of timina to aceount for labour availabilily and market fluctuations. C. THE REINVENTION OF THE HYDROSTATIC SPIRAL PUMP Irrigation, one of the most ancient teehnological innovations in agriculture, has turned many of the earth's sunniest, warmest, and potentially fertile lands into There is growing interest in developing stream-driven water-lifting devices important erop-producing regions. Irrigation has become a eornerstone of global for the irrigation of fields located aboye eanals and streams. The irrigation of food seeurily. Today one third of the global harvest comes from only 17% of the fields with the help of motor pumps is in many cases becoming prohibitive, beca u­ world's irrigated erop lands (Global 2000, 1980; Postel, 1990). This area has se of rising fuel and electricily eosts. The search for eost-efficient water pumps inereased by about 70% from 1952 to 1972, mainly through the inereased use of powered by renewable energy sourees, built out of available materials at the place pumps powered by petroleum and electricily (Fraenkel, 1986). of use, and repairable by local craftsmen is a high research priorily among agricul­ The 250 million ha of irrigated agriculturalland demand some 70% of the tural engineers worldwide. water used worldwide from rivers, lakes, streams, and aquifers. Mueh of this enor­ In this perspeetive, the spiral pump is a remarkable device of great potenti­ mous quantily of water, however, never benefits a erop. The efficiency of irrigation 01. Only recently this stream-driven pump, invented originally in 1746 by H.A. Wirtz (Ewbank 1849), was Jeinvented" almost simultaneously by A.E. Belcher systems averages less than 40% because irrigation works are poorly maintained and operated. Finite water supplies make more effieient irrigation systems a top (1972), R. Ohlemutz (1975) and by P. Morgan (1984). The history of the "Wirtz­ Pump" and first guidelines for the design of spiral pumps are described in a recent priorily in moving towards more sustainable water use (Postel, 1993). The main constraints for the further development of large seale irrigation systems are, other publication by J. West and P. Tailer 11986). scarce water resourees and eeological questions, the high eosts for eonstrue­ tion, fuel and maintenance of the pumps. In the future, small-seale irrigation and efficient water use will become inereasingly important in developing eountries. The large maiorily of the farmers in non-industrialized countries are small-seale farmers 10

11

11. LABORATORY TESTS TO DETERMINE THE EFFICIENCIES UNDER DIFFERENT WORKING CONDITIONS

O. THE WORKING PRINCIPLE OF THE SPIRAL PUMP spiral pump consists of a tube coiled spirally on the same axis and plane, with each succeeding loop having a larger diameter. The whole device resembles a large wheel with the axis parallel to the water surface (Fig. 1 and 2). In the original "Wirtz-Pump" metal tubes were used, which were at that time diffi­ cult to fabricate and bend into a spiral. Additionally, the pumps beca me very . heavy. The introduction of flexible, light-weight plQstic hose was a maior improve­ mento The pump is partially submerged in the stream. Paddles deployed in the streamflow rotate the wheel. Alternating plugs of water and air are scooped into the intake tube (Fig. 1 and 2). To increase water intake, a scoop can be attached. The endof the hose leads into the rotating axle, and by means of a water- and pressure-tight rotary seal (swivel), the water moves into the stationary water-del pipe. During water delivery, the individual plugs in each of the loops are forced against the head, resulting in the buildup of a differential pressure in each of the loops. Water and air are continuously taken in at the open end of the tubeand through the rotation of the pump pressure is built-up and water delivered to higher heads. Figures 1 and 2, modified after an illustration by Olinthus Gregory in 1815 (Gregory, 1815), show the working principie of the spiral pump. With no scooped-in water plugs will travel inside at the bottom of the they are discharged. At an opposing pressure, the individual water plugs are forced against it and are moved to the top of the loops. Figure 1:

Figure 2:

Spirol Pump operating al no opposing pressure

Spiral Pump operoting 01 oppos'¡ng pressure

A. MATERIALS ANO METHOOS Prototype spiral pumps with a 2.0m outer diameter were constructed locally available materials, and different tube material s of different diameters (1.9L 2.54, 3.81, 5.08 and 7.62 cm). To reduce the construction costs materials were selected that were commercially available, even in remote areas. Design of the axle and the two spokes mounting plates: The axle was made out of two galvanized steel pipes of 1.5" (3.81 cm) und 2/1 (5.08 cm) inner diameter pushed into one another and welded together. Special attention has to be directed to the strength of the axle if the distance bet­ ween the two spoke mounting plates exceeds 1.20 meters. To increase of the axle, an additional third galvanized steel pipe of 2.5/1 (3.81 cm) inner dia­ meter can be pushed over the two original pipes and welded together. In the Appendix, detailed design drawings can be found for the axle, with details on the oxle water intake, and the spoke mounting plates. To secure a sturdy attachment of Ihe spokes to the axle, two spoke mounting plates were built out of steel plates with ~teel bars welded to them for extra strength. The dimensions of the component parts depend on the site where the pump is to be installed. The length of the axle depends on the width of the stream or canal. The lengths of the spokes depend on Ihe height from the axle to the water level of the stream.

Design of the bearings: axle is supported by two bearings. Special attention was paid to the construction of the bearings. The bearings need to withstand substantial water pressure, be cheap, and easily replaceable. Conventional water sealedball bea­ rlngs fit to the size of the axle are very expensive. As an alternative, bearings were made out of five similar blocks of hard wood (Shorea astylosa, lIyakal/). The wooden blocks are interchangeable and can be easily replaced. Detailed informa­ ~_IioIIOI.llon about the design of the bearings can be found in the Appendix.

L -________________________

12

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Design of the swivel: One of the most difficult engineering problem during this study was the design and construction of a pressure and water-tight rotary seal, connecting the rotating axle with the stationary delivery pipe. Severa I models using different mate­ 13

rials were designed, evaluated on the availability of the materials, and tested in

field for durability. A swivel with two bal! bearings and a rubber bushing as the

water seal is relatively simple to design IAppendix). This water seal worked

tly and required little maintenance, however, the rubber bushing can be obtained

. only in special rubber supply houses. To overcome the problem with the ovailabili­ ty of the ,wbber bushing, a rotary seal was designed and tested using two ball h"'".-""! rings and a standard oil Ihydraulic KY 47) seal, which proved successful (Appendix). In the two swivels described, the housing and the ball bearings were expensive. For this reason, a rotary seal using a bronze bushing and a standard oil (hydraulic) seal was built and tested. The availability of the bronze bushing of required size posed some problems, and machine-shop work was needed to

trim down the bushing to the needed size.

As an alternative to the bronze bushing, a rotary seal with bearings out of

hard wood (Tristania decorticata, Ifmalabayabaslf) was designed and constructed.

To limit the material costs, standard tube material were used for the housing. In

past, wood from Tristania decorticata saturated with motor oil was used for bea­

rings in ships of the Philippine Navy. This wood is so hard it cannot be cut with a

normal wood saw, much less wifh a machete. Chain saws have to be used to cut

tree. For this reason, Ifmalabayabas" trees can still be found in the Philippines

The search for the most appropriate swivel still leaves many options open and

various possibilities offer further improvement. The models described in the

Appendix are examples that can be refined according to the skill and materials

available.

B. LABORATORY TESTS OF SPIRAL PUMPS To simula'te different flow streams, spiral pumps with different tube sizes

and number of coils were immersed into a rectangular water tank and rotated by

an electric motor with speed-reduction gears. Photo 1 shows a prototype spiral

pump with an outer diameter of 2 m and a spiral with 13 loops made of polyethy­

lene tubing with an inner diameter of 3.81 cm.

To determine the influence of the number of coils on the performance of th

pump, several different numbers of coils per spiral were tested. To vary the amou

of water scooped into the pump, the depth of immersion was changed and water

intake spouts were attached. The water delivered to previously determined heights

was measured gravimetrically.

14

15

For the determination of the maximum torque required to rota te the wheel and of theefciency of the pump under different working conditions, a strain gage (KYOWA type KFC-2-D2-1 1) with a slip-ring was attached to the pump axle, and the results were recorded by a data logger (Omnidata Polycorder). The recorded mV data (80 measurements/min) were converted to kg*m and graphed with the help of LOTUS Version 2.2 Programo The average of the ten highest values of peak was used to determine the maximum torque required to turn the wheel. Al! peak values were used and averaged to obtain the average efficiency. The com­ plete data sets were compiled and calculated by means of the Program dBase Version 3.3 and FoxBase Version 2.1 for the subsequent statistical analysis. Through a multiple linear and non-linear regression analysis, using the IBM mai me computer series 4331 at International Rice Research Institute (IRRI) and Statistical Analysis Systems Program, the influence of each of the different varia on the performance of the pump was determined.

= 0.488

n = 1569

ge tttlciency (%) = 144.81 -180.63In(scd+ 1) +95.302--JSCcI + 10.972 1) -1 .797rpm -14. 9821tcJ + 16.754 In(H+ 1) n 1569 • here: scd = sum of coil diameters (m) = tube diameter . ~v = scoop volume (1) H = head (m) 'pm = rotations per minute ti = number of individual tests _ •• = highly significant at the 0.0001 % leveI

C. RESULTS ,In nearly 1,600 individual test runs, the following variables influencing the performance of the pump were evaluated: 1) water volume delivered per unit time to a defined heíght at a specified rotatíon speed. 2) tube diameter. 3) number of coils in the spiral and the sum of coi! diameters. 4) volume of water scooped ¡nto the pump at each turn of the wheel. 5) maximum torque required to turn the wheel under different working conditions.

6) average efficiency of the spiral pump under different working conditions.

The following relations befween the different factors and the coefficients determination, r2, were established: Max. head (m) = 2200.50 + 642.2 ~ + 5131.88 In(scd+ -6484.74 ~ - 4.14 scd 2 r2 = 0.923** n = 314 formula can be simplified without much loss of reliability: Max. head Iml = 0.97 scd r2 = 0.83** n=277 16

td1.508 rpm O,607

lotal Head: Ihe maximum total head depends on the sum of the coil diameters. The greater the ber and the larger the diameter of the coils, the higher is the achievable maxi­ total head. livered Volume: delivered water volume depends mainly on the diameter of the tube used and speed of rotatíon of the wheel.

fflciency: determiníng the factors which influence the efficiency of the pump, the resear­ '.~h.rs found that the higher the maxímum total head, the lower the rotation speed, smallerthe diameter of the tube used, and with a scoop volume of 100 to '20% of the outer coi! volume, the greater is the efficiency of the spiral pump. The ciency reaches values over 50%: In Figure 3 and ~!, the predicted delivered water volume and the average versus the total head of a pump operatíng at different rotation speeds with different diameter tubes are shown. 17

Figure 3:

Predicted delivered water volume and average efficiency versus total heod at different speeds af ratatian. \

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Head (m) Average Efficiency ("lo) --- Oelivered Volume (11 mi n l

Tube diometer : 4 em Scoop volume . 7.51

Sum eDil diameter 15m

Tube diameter:

The tube diameter determines the amount of water delivered and the efficiency.

rhe smaller the tube diameter the less volume of water can be delivered, although efficiency of the pump with small tubes is higher than with large diameter tubes. I he high efficiencies of the pump running at low speed and with small tube diame­ rs is due to the lower water turbulence inside the smaller tubes. lorque: I he maximum torque required to rotate the pump is mainly determined by the tube md sum of coil diameters. The rotational speed has no impad on the torque requi

od . ter intake

water intake into the spiral depends mainly on he volume of scooped-in water,

he speed of rotation of the pump, and the total head. Regardless of the depth of mmersion of the wheel into the water, and the design of the water intake scoop, it ~ not possible to fill the outer coi! with water to more than 50% of its volume.

Figure 5 shows the results of the volume of water actually scooped in into he tube at different intake volumes. This result was fírst described by Olinthus The delivered volume to a certain head is a positive fundion of the speed of rotali Iregory in 1815 IGregory 1815). However, according to our experiments, a on. Notably low rpm operations offer high efficiencies. The relation between the ~c:oop volume of 100 to 120% of the outer coil proved to be the most efficient size. delivered volume and the efficiency of the pump running with different tube diam IIure 5:lnlake volume versus seoop volume ters is shown in Figure 4. Intoke yolume VS. Scoop volume Figure 4r

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Predicted delivered water vollJme ond average efficiency versus tata I head at differenf tube diom eters.

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Method of stream gauging without the need to build a weir.

The speed of the stream flow at the center can be determined by timing a Root drifting down the stream a predetermined distance (Fi9ure 7). 20

21

Figure 7:

Determination of the speed of ¡he stream flow

Plgure 8: Determination af the height with the help of the water·filled tube method

Determination of the Total Heod with a Measuring Rod and \\tlter-filled Tube

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Oeterminotion of fhe Streom FIow.

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The mean velocity will be 0.60 to 0.85 of this figure. A rough, rocky stream bed requires a factor of 0,6, while smooth muddy surfaces require a factor of 0.85. The flow in m3 /sec is calculated from the product of the mean speed (m/sec) and the area (m2) of the stream cross section. There are many ways to measure the height from the river to the fields to be irrigated. Some involve costly optical equipment, others are require no more than a water-filled tube and two measuring rods, or a wooden board¡ a spirit leve and one measuring rod .. Generally, accuracy to nearest centimeter is not requir'ed to design and determine the needed coil diameters for a spiral pump. To the ca lated discharge head, additional coil diameters are needed to take into account delivery friction and velocity head to obtain the final total pumping head. Two alternatives for measuring the height are the water-filled tube and the bubble level­ plank methods. Water-filled tube method: The water-filled tube is a cheap and sonably accurate method of measuring heights. Two persons are needed to deter­ mine the height with this method plus a water-filled flexible plastic tube, not more than 20 m length, and two measuring rods not longer than 2 meters.

22

Always record

Person A and B mark two places on the slope, place their measuring rods vertically on the marks and stretch the water filled tube between them (Figure 8). The water level in the tube is allowed to settle and the height above each mark is measured at the two rods. The reading of the measuring rod on higher ground is subtracted from the other to determine the first segment height. The procedure of measuring and subtracting is repeated until reaching the level of the fields to be irrigated. The lum of the individual heights gives the total height to which water has to be pum­ pedo The bubble level-plank method: The bubble level-plank method is very simi­ lar. In this method two persons, a wooden plank, a measuring rod, and a bubble Ilvel are needed. The bubble level is attached to a straight wooden plank and the .Ievation is determined with the measuring rod (Figure 9). This procedure is repea­ lid untilreaching the level of the fields to be irrigated. The total height is the sum of all the individual measurements.

23

"tu,. 91

IV. POWER REQUIREMENTS TO DRIVE A SPIRAL PUMP

Oe'e,mlnnlltm tlf 111.. h..IOhl with Ihe help of the bubble level-plank method

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The power requirements and alternative power sources to drive a spiral pump hove been clearly described by Fraenkel (1986). Energy is removed from lIowing water to drive the spiral pump. The energy requirement consists of the pro­ duct of power and time. A specific amount of work can be done quickly using a of power, or slowly using less power, but in the end the identical amount of nnergy is required. The required and the available power have to be determined lo successfully design a pump. The power P needed to deliver a water volume Q 11/ sec) to a head of H (m) is:

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Power requirement: If Q is in m3/sec, then the aboye formula gives P in kW. Theoretically, 9.8kW are required to deliver a flow of 1m3/sec to a static head of one meter. The actual power requirements will be higher beca use of system ineffi­ clency. A spiral pump with a total efficiency of 25% will need four times the amo­ unt of power. The Watt (W) and kilowatt (kW) are the recommended international units of power, but units such as horsepower (where 1 hp = 0.746 kW) are still in use in some places.

A.

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9.8 * Q * H (Watts) where : 9.8 is the gravitational constant (in m/sec2 )

WATER-POWER to drive a spiral pump

Available energy: The kinetic energy P available in a stream is proportional to the cube of the velocity.

P= 1/2 * p * A*v 3 (Watts) where p is the density of water (1 kg/I for fresh water)

A is the orea of cross section of the current in m2

B

vis the mean velocity through the cross section in m/sec From

formula the following power densities can be calculated

Head with Measuring Rod and Bubble Level 25

Figure 10: Power density in streams os o function of the water speed per unit orea of the water stream

POWER DENSITY IN WATER CURRENTS AS A FUNCTlON OF THE WATER VELOCITY 300

-e :s: -.­-.,.

whore the current can be used to lift water, which would otherwise flow along dry flulds. Even in some wetter and more mountainous areas, there ore situations where water power could allow irrigation of terraces or plateaus ínaccessible to flow. This is important where flat land with fertile soil is scorce. Given a suitable site in proximity to a suitable need, hydropower has a lIumber of important and fundamental attractions:

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1) It is generally available 24

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2) It is a relatively concentrated energy source

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3) The. available energy is easily predictable lO

4) It has a high power to size ratio, and hence favorable power to cost ratio

50

5) Pumps driven by hydropower tend to be mechanically simple and O 2

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Water VeJocity (m/sec) Power availability is extremely sensitive to the water speed, Wlth a relo'lon.hlp. Daubling the water speed increases the power availability by a fac­ tor of Ileh', Par thl, reason, the best way to increase available power is by inc .Ingltrllm '1lloclty using channelling, or by forcing the water straight into the spi­ rol

pu"',.

c,;_' power as an energy resource to drive a spiral pump has two basic One, It is only available for practica I use in those limited locations water flows. Two, most regions with hydropower potential tend to 11 1 at least during a couple of months, which makes irrigation 'hese drawbacks, there are many oreas where rainfall or water e.9. where water can usefully applied during the hot dry summer mountainous oreas, where snow melt often provides some limited thl dry summer season. opplications for using of waterpower with the spiral pump is to would not be accessible to gravity water flow. In some arid regi­ dry seasons, there are perennial rivers and irrigation canals

robust, have long working lives, and require limited and simple maintenance. As a result, hydropower can be one of the most economical sources of power for those fortunate enough to have a suitable resource available.

Making Use of the Hydro-Power The traditional way using of the power of streams are undershot and overs­ hot water wheels. They are relatively ¡neffident, since most of the wheel is out of the water stream and therefore only a small part of the wheel can catch the stream flow. In working with waterwheels efficiencies can be achieved of 30 to 50% for undershot, and 50 to 70% for overshot waterwheels. The delivered volume to certain total heads at different flows can be calcu­ loted. Knowing the stream speed and from this, the available stream power to drive a spiral pump (see Figure 16 from Step 3 of the Guidelines of how to predict tne delivered volume) with a known paddle area and overall efficiency. The total nead and the delivered volume at different flows is related (Figure 11). As expec­ ted, the higher the flow, the more water can be delivered to high heads.

27

Figure 11: Relatian belween total head and delivered valume at diflerent flaws.

\lood salary for a farm worker is in the range of US $ 5/day, which gives an "l1ergy cost for 1 kWh of about US $. Less than one liter of fuel for a price of ubout US $ 0.5 is needed to run a small engine to produce 1kWh of energy. This "xample demonstrates clearly, contrary to popular belief, muscle power is not cheap. The poor are forced to use their muscles, since muscle power is for them Ihe only affordable option. There is an opportunity cost caused by diverting peo­ pie from more important work to use manual labour to pump water. The best asset poople have are their brains rather than their muscles; therefore, if agricultural pro­ ductivity is to improve and economic standards are to be advanced, it is essential ID introduce more productive power sources.

Slr,cm Po.erad SpircJ Pump Hlod VI. D.livered Volu me M Di"eren, Streom Flows.

20

Aseumptions: Paddlt Arta: 0.6m Paddle Ettici.ncy: 0.6 Spiral Pump Ettlci8ncy: 0.4

18

16

e

14

.

12

.",

c:o

~

2­

o 1­

Over·GlI ffticiency: 024

1.5.w 1.2~m/s

10

B

6 4 2 O O

2

3

4

~

6

Delivered Volume (m 3/ hr)

7

8

9

10

B. ALTERNATlVE POWER SOURCES TO DRIVE THE SPIRAL PUMP DURING TIMES OF LOW FLOW.

Spiral pumps are useful even during dry seasons and declining stream flows. During the dry periods when the streams become shallow, the stream flow tnight not be sufficient to drive the spiral pump. During this unfortunate situation Ihe spiral pump can be effectively operated by human power. Figure 12 details the water volume delivered in one hour to different heads, when the pump is opera­ ted by one, two, and three persons. Plgure 12: Spiral Pump "peroted by human pawer: ~"Ialian belween the deliver· nd volume (m3) in ane hour 1" different total heads.

Human Powered Spirol Pump Head vs. Delivered Volume 2O 18

I Human Energ, Availablelar 1hr : 31.25 IV hr Spirol Pump Ellitienc,: 40 %

16

1. Human power People (and animals) derive power from the calorific content of their food. Even when physically inactive, the human body requires energy to run its basic metabolic functions, i.e. to power the heart and circulate blood, to keep the body 0 temperature at 37 ( , etc. Energy for muscle power is then an extra requirement on top of this. For humans a typical food energy requirement per day is around 2 400 kcal or 2.8 kWh. A person's muscular work capability is in the region of 1 to 300 Watthours per day, depending on the gender, the age, state of health, weight, and duration of effort. For a very short period the maximum power outpu can reach up t0400 Watts. Human beings have an average overall efficiency in the region of 7 to 11 % for converting food energy to mechanicalllshaft energy". Average human work capability is about of 250 Watthours per day; meaning four days of hard labour to deliver only 1 kWh. A small engine could deliver this a unt in less than one hour while burning less than one liter of fossil fuel. Not surpri. singly, any farmer who can afford it will choose to employ an engine rather than human muscular power. To describe this fact more drastically: In the Philippines,

14 12 10

8 6 4

2J

O

O

==:= .- - - - -. - -.- -. - . . -­

j

2

3

i

I

¡

i

4

5

6

7

---~---- .. -~-- .. --­

8

9

~ '0

Delivered Volume (m' / hr)

I­

I person

----­ 2 persons -

3 persons

Figure 13 shows, in the case of a low water stream, how the rotation of the spiral pump can be increased by a person standing on the support system for the pump. Of course, the pulling down of the wheel with the hands is not the most efficient way to use the limited human energy.

28

29

Figure 13:

figure 14 shows a more energy efficient method of using the spiral pump in sta­ unant water. While labour intensive, spiral pumps are much more labour efficient other manual irrigation systems.

The rotation of the Spiral pump increased through non power by pulling down ¡he wheel with the honds.

"gure 14: Operating ¡he spirol pump in stognant water

J~'~

ro

~- .~.­ '~~>'i;::l',--.~

J

\ \

~-Jf!'-~-~ r~1~,«'C:L· 7·' . ' - ­

,.fr·~· -r./

30

31

2. Animal power Tnere are two advantages of using animal power over human power: al draft animals are five to ten times more powerful than humans, so they can pump more water in a shorter time, which makes the irrigatíon operation more efficient and productive, and b) by freeing the farmer from having to work the water-liftin device, he can manage the water distribution system more effectively. In effect, use of an animal provides the equivalent power of several people, generally at a fraction of the costo

V. ALTERNATIVE WATER LlFTING DEVICES WHICH USE

HYDROPOWER TO DEELlVER WATER TO A HIGHER HEAD

THAN THE PUMP STRUCTURE ITSELF

Several alternative watef lifting devices using hydropower are available to small seale farmers. The major alternative pumps are: coil, ram and turbine pumps.

A. THE COIL PUMP Thecoil pump has the same working principie as the spiral pump, but the design differs significantly. In the coil pump, flexible tubing is wound concen around a drum or floating framework. Therefore each of the loops has the same diameter, and the dimensions of the drum as well of the tubing determine the num­ ber and diameters of the loops coiled around the drum. A.E. Belcher described (Belcher 1972) a coil pump, and in 1984 provided the Danish Guide and Scout Association a detailed description of the design and technology of coil pumps. In laboratory tests Haeusser (1995) described the impact of the rotational speed, the submergence of the coil pump into the water, and the number of coils on the effi­ ciency of water delivery to different heights. Reimer (1985) described the perfor­ mance of the pump under field tests. Two important limitations have been noted with coil pumps. One, the applicable dimensions of the drum create serious lim ons for the operation of coil pumps in narrow irrigation canals. Two, pressure bui!­ dup can be observed in spiral pumps with only two loops. This is in contrast to experimental findings with coil pumps, where pressure buildup does not occur until . or after the fourth loop (Collett 1981). Recently, Hilton (1986 and 1989) descri­ bed an inclined coil pump using a water tight cylindrical drum as the coil support structure. His coil pump had an outer diameter of only 0.75 m, can be operated by man, and does not require a rotary sea\. This of course facilitates the construc­ tion. However, he recommends the inclined coil pump for lifting water only one to four meters.

32

8. THE HYDRAULlC RAM PUMP Ram pumps were first developed in 1796 by the Montgolfier brothers in I rance, and have been used for nearly two centuries. They are powered by the tll1ergy of a large amount of water falling a short distance to lift a smaller amount uf water to a much greater elevation. Ram pumps, however, can lift only a fraction of the flow that drives the pump. Wherever a fall of water can be obtained, the 10m pump can be used to lift water to considerable.heights with efficiencies of 50 3 lo 80%. At a drive flow of 90 I/min and a delivery head of 60 m, about 12 m of water can be delivered with a DTU ram pump in 24 hours Ueffery, 1992). Hydraulic rams are comparatively cheap and mechanically extremely simple, which r9sults in a very high reliability, combined with minimal maintenance requirements Clnd a long operational life. Fraenkel (1986) published a very informative descrip­ tion about the installation requirements, the design choice, and performance cha­ rocteristics for hydraulic rams. The Development Technology Unit of the University of Warwick has published an excellent guide to ram pump design and operation in which detailed information can be found about the components, local manufacture, ond system design (Jeffrey, 1992)

c. TURBINE PUMPS Axial-flow turbine pumps are attractive in situations where the energy of high water f10w can be used to deliver water to low heads. These are the most technically sophisticated and costly pumps and thus, not suitable in many situations designed to assist small-scale farmers. According to Fraenkel (1986) a typical Chinese turbine pump operating in a flow of 210 to 420 1/ sec can deliver 21 to 42 I/sec of water to a lift of 6 to 24 m. The overall efficiency is 30 to 50%. Turbine pumps are generally for low head applications, where the hydropower source will often be a canal pi unge in an irrigation scheme or a weir on a canali­ zed river yielding a head height of 1 to 15 m. Typically, turbine pumps are used for the irrigation of commercial crops on lowland farms. They are typically instal­ led on a concrete platform built into a weir. Although the pump unit is relatively inexpensive, civil works represent the largest cost element. The efficiency of turbine pumps relates to the speed of rotation at different heads and stream flows. For this reason, there are many different types of turbine pumps on the market: . propeller turbines (Iow heads), Francis turbines (medium heads) and Pelton and Turgoturbi­ nes (high heads). Turbine pumps are relatively complex. For a local craftsman in a developing country, it is generally impossible to build these complicated high-tech turbine pumps.

33

It is possible to connect the shaft of the turbine directly to a generator, whiCh can be used to power an electric pump for irrigation, or the shaft of the tu bine can be coupled to a centrifugal or rotodynamic pump. Converting shaft power to electricity, transmitting the electricíty to an electric pump and converting back to shaft power reduces the original turbine efficiency considerably. Another possibility uses the flow of a river by coupling turbine rotors on a single shaft Iy to two opposed single-acting piston pumps via a crank. Normally, turbine-pi pumps ore designed to operate at low heads, but they are capable of generating hígh total heads of over 100 m. However, this type of turbo-pump is more com than other turbine-centrifugal or turbine-rotodynamic pump combinations, and the construction is out of reach of a local craftsman in a developing country.

rhe number of coils in a wheel should not exceed 10, and the difference of the dia­ meters of the outer and inner coil should not be too large. 2) Determine the outer diameter of the spiral pump: The outer diameter of the wheel depends on the location where the spiral pump is to be installed. The shape of the dike for the installation of the spiral pump support structures or the design of the float, determine the size of the spokes the wheel. Smaller wheels have a higher speed of rotation at the same flow compared with large wheels. Because the delivered volume depends mainly on ¡he speed of rotation of the wheel, small wheels are preferable. 3) Determine the available water power in the stream

VI. GUIDELlNES OF HOW YO PREDICY YHE DELlVERED WAYER VOLUME WITH A SPIRAL PUMP AY A GIVEN YO A GIVEN HEAD.

o) Determination of the power density(P) P= 0.5 p * A * v3 (Watts) Where: p = density of the water (1 000

The relationship between the different variables that influence the effici of the spiral pump was evaluated from the laboratory tests. The following step step approach explains, how to design a spiral pump and to predict the delive water volume at a given flow to a given head. 1) Determine the needed sum of coil diameters for pumping to a certaín head.: This simplified formula can be used for the determination of the maximum total head: Max. head (m) = 0.97scd

= sum

Where: scd

Figure 15:

Maximum head

"'SUS

A = area of the cross section of the current 1m2) v = mean speed of the stream through the cross section (m/sec) b) Determination of the power available for the pump P= 0.5 p * A * v3 IWattsJ

of coil

Where: p = density of the water (1000 kg/m 3 for fresh water)

Determination of MaximullI lIead

Determinotion 01 the maximum head

kgl m3 for fresh water)

sum ~ail diamela,s

20 o

E

. ....

A

o

18 16

of

stream swept orea of the paddles 1m2)

v = mean speed of paddles (m/sec)

o

Mhead =0.97 $~d ,=091" .• = 277

'" 14

= area

o

stream through the cross section of the

:x: 12 Ii =>

.! :lE

1O

8

sJ

o o

4 4

6

8

la

12

Sum of Coil Diameters (111)

34

14

16

le

Ideally, the water power in the canal should equal the power available at the pump. In reality, only a fraction of the available power can be used by the paddles. The relation between the stream speed and the available power is shown In Figure 16. In this figure the following assumptions were made: paddle area 0.6 m2 and an overal! efficiency of the spiral pump of 24% Ipaddle efficiency = 60%, spiral pump efficiency = 40%)

35

Figure 16:

Slreom Velocity

Relationship bet­ ween streom speed and available power.

i..

YS.

Availoble Power

Auumptions: Poddl. Arto: 0,6 me Oyer-all Efficiency: 0,24

; ce

.

:c; .s! 'c;

...'"

maximum head and the sum of coil diameters are given and the mini­ torque requirements to drive the pump could be calculated by step :1 and 4. Thus, the diameter of the tube to be used can be theoretically determi­ ned. Figure 17 shows Ihe relation between the stream speed (m/sec) and the rnaximum tube diameter (cm). The following assumptions were made: wheel dia­ meter 2.00 m; paddle size = 0.6 m2, drag coefficient = 0.3, and a total head of 10.00 m. Plgure 17:

Determinolion of Muimum Size of Tube Diameters rube Oiometer versus Slreom Ve/oelt,

~"Iotionship between ,!100m speed (m/sec) "lid the maximum m "In of tube diamelers

6.0--r,-----------------------¡

E..,

-

Assumptions: Wheel diamefer 2 Poddle size: 0.6 Droq coe!f. 0.3 rlead: 10 m

5,5

G>

O; 5,0

eCJ

i5

..,....

4.5

=>

y: ­ 2,5 + 4,84 Stream Ve 1. r 2 =0,82 u , 0=314

1­

E 4,0

4) Reformulate the available power (Watts) in torque (kg*m) to determine the lable torque to drive a spiral pump. Torque (kg*m) = Power (Walts) * area of the cross section of the stream (m*sec 2) 5) Compare the available torque in the stream and the maximum torque required drive a pump with 100% efficiency The variables that influence the torque requirements to drive a spiral were determined through the laboratorytests, and summarized in the following Maximum Torque (kg*m) = -642.07 - 108.797scd + 1.462scd 2 +499. 387v'SCd + 0.00480sv3 +0.61 td 2 + 4.726 In(H+ 1) r2 = 0.82** n = 1569 Where: scd = sum of coil diameters (m) td = tube diameter . sv = scoop volume (I) H = head (m) n = number of individual tests ** = highly significant at the 0.0001% level 36

:::>

E K

~ 3.5

3.0

I

,

¡

¡

¡

I

12

1.3

lA

1.5

1.6

1.7

Streom Velocily (m!sec)

The higher the stream speed, Ihe larger the lube diameter that can be used. The efficiency decreases, however, when using large tube diameters. For reason, il is advisable lo use two or more tubes of the same total cross section orea, instead of one large tube. The maximum torque lo rotate Ihe pump is mainly determined by the tube diameter and the sum of coi! diameters. For actual operati­ ons, the sum of coil diameters should not exceed the requiredgross pumping head, ond a tube diameter has to be chosen which matches Ihe kinelíc energy of the stra­ om flow. This formula is valid for only one tube in the pump. Operation with two spirals in Ihe pump requires twice as much torque. 6) Estimate the overall efficiency of the spiral pump: An additional torque (stream flow) is required to drive the spiral pump to compensate for the inefficiency of the pump and the drag coefficients of the padd­ les. In laboratory tesIs, spiral pumps operated al efficiencies of between 40 and

37

50%, depending on the speed of rotation and the tube diameters. During the la ratory tests the pump was powered by an electric motor and the efficiency was determined at the axle. During field operations, the spiral pump operates Iike an. undershot waterwheel and is driven by paddles, which reduces significantly the ·overal! efficiency. Undershot waterwheels general!y have an efficiency of only to 40%. The drag coefficients of the paddles, depend on the paddle design, her reduce the pump efficiency. lt thus seems reasonable to consider the overal! ciency of the spiral pump as 20 to 35%.

figure 18:

Estimotion of Defívered Vofume ot 5m Heod

I ,timotion 01

Al different tobe diamelers and stream velocities

tilO delivered volume to o ¡otal heod 01 " mwilh different tube diometers ond ,heom speeds.

From Fiefd Tesis 50~1-------------------------------------------

c::

's ......

.

30

E

::J

3.9 cm (1.5") díom.

o

>

...

....,

SV O.402

=

20

~

In the laboratory tests for the estimation of the delivered volume under

rent working conditions of the spiral pump, the following formula was derived :

Delivered volume (I/min) = 0.488

Wheel diameler. 2m 2 Elleclive poddle size: 0.6 m

40

7) Estimate the delivered volume to different heads with different tube diameters and at different stream flows:

td1. 508

5.1 cm (2") diom.

A55um plions:

-.; o

3.2 cm(r. 2S')diam.

10

_ - - . - 2.5cm(l")diom.

rpm O.607

oI

H ·0257

1.2

I

I

I

i

I

1.3

1,4

1.5

1.6

1.7

I

1.8

Stream Velocity (m/sec)

r2

= 0.93** n = 1569

Where:

td = tube diameter (cm)

sv = scoop volume (1)

H = head (m)

rpm = rotations per minute

n = number of individual tests

* * = highly significant at the 0.0001% level

In this formula, the tube diameter and the speed of rotation are the most importa fadors that determine the amount of water delivered to a given head. However, with this formula it was impossible for us to estimate the delivered volume. The laboratory pump was powered by an electric motor and run without paddles, we could thus not relate the speed of rotation of the wheel at different f1ows, different tube diameters, and different total heads. With the help of the field test data, this problem could be solved. In Figures 18! 19! and 20 the relation between the del vered volume to different heads, with different tube diameters and stream speeds shown.

38

ro m Head

Estímation of Delivered Volume at

figure 19: Estimotion of the delivered volume to o total heod 01 10.00 ró with diflerent tube diometers ond Itreom speeds.

Al different tu be diamelers ond stream velocit ies from fields tests 40il----------------------------------------------~

e

e

......

1

35

Assumplions:

-­

~Ucm {tI diom.

Wheel diometer • 2 m Effecf¡ve poddle $ize: 0.6 m!

30

:: 25

e::1

38 cm (1. 5") diom

"O 20

>

"O

.. .¡¡ ...~

o

15 10

5

ot

1.2

I

t

1

1.3

1.4

1.5

i

i

,

1.6

1.7

18

Streom Velocíty (m/sec)

39

Figure 20:

Esfímation of Delivered Volume ot 15 m Heod

Estímalion 01

lhe delivered volume lo a

total head

0115 m wíth

different lube diamelers

and stream speed.

At different tube diamefers and stream velociti es

from fields tests

VII. FIELD TESTS OF SPIRAL PUMPS UNDER ACTUAL FIELD CONDITIONS IN ABRA, NORTHERN PHILlPPINES

1----------------------.,..-.---...., ____ 5.1 cm 12") diom.

351 30

A. ABSTRACT

Assumplions:

Wheel díameter 2m Effeclíve paddfe size 0.6 mZ

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