REPUBLIC OF RWANDA

MINISTRY OF INFRASTRUCTURE

Training Module
on
Operation and Maintenance of Pumps
in
Rural Water Supply Systems

Edition 3.0

May 2019
 REPUBLIC OF RWANDA

MINISTRY OF INFRASTRUCTURE

Training Module
on
Operation and Maintenance of Pumps
in
Rural Water Supply Systems

Edition 3.0

May 2019
 Training Module on O&M of Pumps in Rural Water Supply Systems

PREFACE

Access to safe drinking water is crucial, not only for people’s health and wellbeing, but also for
poverty reduction and economic development;
Improving the access, quality, availability and sustainability of water supply services in RWANDA
is the top priority in the Sector;
Rwanda has committed to reach SDGs targets by 2030 through the different programs such as the
NST1 and 7 Years Government Program with the aim of achieving universal access to basic water
and sanitation services by 2024. In order to achieve this target, an appropriate institutional system has
to be in place.
The development of the National guidelines for Sustainable Rural Water Supply Services and all its
supporting documents (Manuals, Training Modules, etc.) is part of the mechanism to develop the
Operation and Maintenance in the Rural Water Supply, and make an important guidelines to Districts,
Private Operators, User communities and all the stakeholders in the Rural Water Supply Services sub-
sector.
I want to extend my appreciation to the stakeholders, especially JICA/RWANDA through the
RWASOM Project, for the effort to have these important documents in place.
We look forward to positive impact of the developed documents through the O&M framework in the
rural water services, sustainability of existing water infrastructures and overall, an improved and
sustainable clean water supply service toward the communities in RWANDA.

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 Training Module on O&M of Pumps in Rural Water Supply Systems

ACKNOWLEDGEMENT

Many stakeholders in the water sector have tried to develop training modules adapted to the
systems they have made. The content of this training module is based on WSP modules
written by Philippe Casterman. Great thanks are own to him.

Edition 1.0 of this training module was composed by engineers of AquaRwanda Consultants.

Edition 2.0 of this training module is directed by PWN/Aquanet as part of the SUSWAS - project.

This edition 3.0 of the training module is revised by the Project for Strengthening Operation and
Maintenance of Rural Water Supply Systems in Rwanda by WASAC and JICA.

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 Training Module on O&M of Pumps in Rural Water Supply Systems

TABLE OF CONTENTS

1 Lesson 1: GENERAL INTRODUCTION...................................................................... 1

1.1 Introduction ................................................................................................................................. 1

1.2 Training module objective ........................................................................................................... 1

1.3 Module description ...................................................................................................................... 1

1.4 Target group ................................................................................................................................ 2

1.5 Methodology ............................................................................................................................... 2

1.6 Expected benefit /outcome .......................................................................................................... 2

2 Lesson 2: MANAGEMENT ASPECTS ........................................................................ 3

2.1 Operation and Maintenance......................................................................................................... 3

2.1.1 Definitions .............................................................................................................................. 3

2.1.2 Organizing the operation ........................................................................................................ 4
2.1.3 Maintenance planning............................................................................................................. 4
2.1.4 Key issues ............................................................................................................................... 4
2.2 Safety Regulations....................................................................................................................... 5

2.3 Record activities, follow up and analysis .................................................................................... 6

2.4 Responsibilities of the personnel ................................................................................................. 6

2.5 Tools ............................................................................................................................................ 7

2.6 Spare Parts ................................................................................................................................... 7

3 Lesson 3: Overview of Water Supply .......................................................................... 9

3.1 Sources of water .......................................................................................................................... 9

3.1.1 Groundwater ........................................................................................................................... 9

3.1.2 Rainwater ................................................................................................................................ 9
3.1.3 Surface Water ......................................................................................................................... 9
3.2 Types of distribution systems ...................................................................................................... 9

3.2.1 Gravity systems .................................................................................................................... 10

3.2.2 Pumped systems.................................................................................................................... 10

4 Lesson 4: PUMPING STATION GENERAL .............................................................. 12

4.1 Description and background information .................................................................................. 12

4.2 Operation ................................................................................................................................... 15

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 Training Module on O&M of Pumps in Rural Water Supply Systems

4.3 Preventive Maintenance ............................................................................................................ 16

4.4 Curative Maintenance ............................................................................................................... 16

5 Lesson 5: PUMPS .................................................................................................... 17

5.1 All pumps .................................................................................................................................. 17

5.1.1 Description and background information ............................................................................. 17

5.1.2 Operation .............................................................................................................................. 18
5.2 Centrifugal pump....................................................................................................................... 21

5.2.1 Description and background information ............................................................................. 21

5.2.2 Operation .............................................................................................................................. 21
5.2.3 Preventive maintenance ........................................................................................................ 22
5.2.4 Curative maintenance ........................................................................................................... 22
5.3 Submersible pump ..................................................................................................................... 23

5.3.1 Description and background information ............................................................................. 23

5.3.2 Operation .............................................................................................................................. 24
5.3.3 Preventive maintenance ........................................................................................................ 24
5.3.4 Curative maintenance ........................................................................................................... 24
5.4 Hand pump ................................................................................................................................ 26

5.4.1 Introduction .......................................................................................................................... 26

5.4.2 AFRIDEV Hand Pump ......................................................................................................... 26
5.4.3 India Mark II hand Pump ...................................................................................................... 45
5.4.4 Disinfection .......................................................................................................................... 66
5.5 Turbo pump ............................................................................................................................... 68

5.5.1 Description and background information ............................................................................. 68

5.6 Hydraulic ram............................................................................................................................ 69

5.6.1 Description and background information ............................................................................. 69

5.6.2 Operation .............................................................................................................................. 71
5.6.3 Preventive maintenance ........................................................................................................ 71
5.6.4 Curative maintenance ........................................................................................................... 71

6 Lesson 6: POWER DRIVERS ................................................................................... 72

6.1 Power supply ............................................................................................................................. 72

6.2 Diesel Engine ............................................................................................................................ 72

6.2.1 Description and background information ............................................................................. 72

6.2.2 Preventive maintenance ........................................................................................................ 72
6.3 Electrical Engine ....................................................................................................................... 73

6.3.1 Description and background information ............................................................................. 73

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6.3.2 Preventive maintenance ........................................................................................................ 73

7 Lesson 7: SOURCES OF ENERGY ......................................................................... 75

7.1 Diesel......................................................................................................................................... 75

7.2 Electrical Grid ........................................................................................................................... 75

7.3 Electrical Generator................................................................................................................... 75

7.4 Solar Power ............................................................................................................................... 75

7.5 Hydopower ................................................................................................................................ 75

7.6 Human Power ............................................................................................................................ 75

REFERENCES.......................................................................................................................... 77

ANNEXES ................................................................................................................................. 78

Annex I: water meters at a pumping station ....................................................................................... 79

Annex II: Hydraulical background information ................................................................................. 80

Annex III: Tools ................................................................................................................................. 87

Annex IV: Site exercise...................................................................................................................... 89

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PARAMETERS

PARAMETER SYMBOL UNIT SYMBOL

pressure relative to h meter water column Mwc

atmosferic pressure,
head

bar Bar

Pascal Pa

elevation / distance to z meter M

reference level

Force F Newton N

headloss per meter j meter water column per mwc/m

meter length

Power P Watt W

1000 Volt Ampère kVA = kW

Length L meter M

discharge / flow Q cubic meter per second m3/s

liters per second ℓ/s

efficiency η percentage %

revolution r revolution per minute r/min

surface A square meters m2

velocity / speed v meter per second m/s

volume V cubic meter m3

gravity constant g meter per square m/s2

second

density ρ kilogram per cubic kg/m3

meter

friction coefficient λ [-]

wallroughness k meter M

D diameter meter M

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ACRONYMS AND ABBREVIATION

ABBREVIATION CLARIFICATION

AC Alternating Current

DC Direct Current

EG Electrical Generator

JICA Japan International Cooperation Agency

MININFRA Ministry of Infrastructure

O&M Operation and Maintenance

Qn nominal flow

RWSS Rural Water Supply System

WASAC Ltd Water And Sanitation Corporation

WHO World Health Organisation

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1 Lesson 1: GENERAL INTRODUCTION

1.1 Introduction
In general, a water supply system consists of infrastructure for catchment, for treatment, for
storage, for pumping and for distribution of potable water. Infrastructure for pumping is only
necessary when natural elevations of the area are not enough to overcome energy losses. If
water is produced on a high location the water can flow by gravity to the consumers.
In this training module the operation and maintenance (O&M) of infrastructure for pumping, is
described. All other infrastructure is taken care of in the other training module ‘Training
Module on O&M of Gravitational Rural Water Supply Systems’.
In the past, insufficient O&M led to a short life span of the infrastructure. Sustainable O&M of
rural water supply infrastructure is the key challenge of drinking water supply.

The number of pumping stations goes on increasing in the rural area of Rwanda because of the
intensification of the agglomerations (imidugudu) on the hilltops and the location of drinking
water sources in lowland valleys.

1.2 Training module objective

The objective of this module is to provide practical knowledge to operate and maintain
pumping stations and associated electrical and mechanical equipment.

1.3 Module description

This module is not a theoretical course on pumps. This module gives the practical knowledge that
the operator of the pumping station must have with respect to the ensuring sustainability of the
installation. This module contains less text but figures and tables to illustrate the reality of
equipment.

This module focus on:

• Good understanding of the functions of the various elements that may be encountered in
any rural pumping station in Rwanda.
• An understanding of O&M activities required in order to plan, budget, schedule and
monitor them.

The main items developed are:

• Management aspects;
• Overview of water supply preliminary;
• Configuration of a pumping station;
• Type of pumps;
• Power supply;
• Sources of energy.

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From every asset the following items are discussed:

• Description and background information;
• Operation;
• Preventive maintenance;
• Curative maintenance.

1.4 Target group

The development of the training module is in line to respond to a call for a comprehensive
capacity development addressing to both districts and private operator’s staff involved in the
operation and maintenance.

This training module is specifically dedicated to increase the skills of WASH-officers, technical
directors, plumbers, water treatment operators and other water technicians responsible for
daily monitor the functionality of RWSS. The minimum pre-qualification required for the
trainees is A3 grade level.

1.5 Methodology
By this method based on prepared notes, the trainer will expose and calls to trainees to react and
exchange ideas.
The training must preferably be held near a pumping station well equipped with appropriate tools.
Participative approach by which trainees will express their ideas without shame; The trainers will
take into consideration the participants expectations on the learning objectives and on what
topics is likely more interesting in.
The trainers have to use video projection, questions, exercises, and practice on the field.

1.6 Expected benefit /outcome

Upon completion of the module the participants have significantly increased their knowledge of
the operation and maintenance of a pumped system.
• The technical and managerial skills are improved for better participating in the design, the
work surveillance during the implementation, technical consideration during O&M.
• The private operator will be empowered in technical skills of O&M and will effectively
improve the working condition in ensure the functionality and reliability of the water
supply system.
• The district will improve the follow up of the delegation management contract.
• Improvement of reporting system on both districts and private operator using the developed
tools for monitoring.
• This module will be used country wide as a basic supporting tools in the O&M of RWSS.

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2 Lesson 2: MANAGEMENT ASPECTS

2.1 Operation and Maintenance
2.1.1 Definitions

Operation: All daily actions to secure the drinking water supply to the customers.

Operation refers to timely and daily operation of the assets of a RWSS effectively by various
technical personnel in order to provide safe drinking water under adequate pressure to all
customers. Some examples:
• Start and stop a pump;
• Open and close a valve;
• Add chemicals to the water;
• Fill the buckets at the public tap;
• Read the water meter.

Maintenance: All actions that keep the assets of the system in a proper working order during their
life-cycle.

There are two types of maintenance:

Preventive maintenance: are actions that performed on a regular schedule to keep assets operating
effectively and to minimize unforeseen failures.

These actions consist of inspections and maintenance tasks.

Some examples:
• Change engine-oil of a pump;
• Grease rotating parts of a motor;
• Flush a distribution system without complaints;
• Repaint the connecting mains to a reservoir;
• Inspect the functioning of a valve.

Curative maintenance: Actions performed to repair or restore malfunctioning assets to effective

operating conditions.

These actions may result from problems discovered during preventive maintenance or as a
result of failures during operation.
Some examples:

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 Training Module on O&M of Pumps in Rural Water Supply Systems

• Repair a broken main;

• Repair a worn out impeller of pump
• Replace a failing water meter
The replacement of a main after having too many ruptures is not called curative maintenance. This
is called replacement for which financial investments are needed.

2.1.2 Organizing the operation

Operations aims to keep the system in service continuously or at least during service hours.
According to the operating environment the manager will decide on the appropriate course of
actions.
The Manager must have clear overview of vital day-to-day activities and avail technical
specifications of all installed equipment from the manufacturers and suppliers, identify the
appropriate tools and study of logistics needs.
Establish the need for parts and consumables, and enter these elements to the annual budget.

2.1.3 Maintenance planning

Preventive Maintenance is planned.
• An action plan for the year, with the financial budget and the human resources
appropriate.
• The action plan will be broken down by months and even weeks for some tasks to be more
precise.
Maintenance is a form of insurance in the medium and long term, allowing assets reaching their
normal life (that provided by the manufacturer or constructor).
• Sometimes the maintenance is neglected because it costs money or is has no clear and
immediate impact.
It is important for managers to estimate the cost of maintenance in their budget, which will affect
the price of the service.
• The Operator must be in position to calculate the cost which will cover all the operation
and maintenance activities.

2.1.4 Key issues

Some of the key issues contributing to the poor O&M have been identified as follows:
• Budgeting:
Lack of finance for proper maintenance.
• Monitoring:
Lack of performance evaluation and regular monitoring. The monitoring gives the
managers the opportunity to learn from the impact of executed O&M works, inadequate
data and real time field information.
• Standardization:
Inappropriate system design; The standardization greatly improves the efficiency of O&M
in reducing costs, facilitating learning, allowing the exchange of parts, tools, and
experiences between operators, lack of operation manuals, guidelines and operational
strategy at all levels

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• Human resources:
Inadequate training of personnel. This affects proper monitoring during implementation
and O&M. This can also result to less attraction of maintenance jobs in career planning.
• Appropriate technologies:
Appropriate technologies are those that are adapted to the local context. The choice of
appropriate technologies can promote O&M scope of local actors, technically and
financially, or otherwise this will make it difficult and leading to low sustainability of the
service. Lack of appreciation of the importance of facilities by the community.
• Example:
A water treatment requiring a chemist and laboratory with reagents, is not suitable for a
system supplying water to only 4,000 rural customers consuming less than 10 liters a
day.

2.2 Safety Regulations

Special attention must be taken to the following words before the O&M of any equipment or unit
in drinking water facility like a catchment area, a treatment plant, a storage reservoir or a pump
station:

Safety must be ensured continually. It will be adapted to each situation by following this few
guideline:
• The drinking water facility must be closed. Access to this area is prohibited to any person
not authorized by the Operator. The note ban should be displayed.
• All visitors must be registered (visitors lists in registration book kept in the drinking water
facility).
• The reserve of fuel, lubricants and reagents must be closed and kept clean.
• It is forbidden to smoke and to make fire within the confines of the drinking water facility.
This must be displayed visibly.
• The emergency stop instructions should be highlighted.
• The telephone numbers of emergency contacts (manager, police or local authorities,
doctor, nurse) should be displayed.

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• First aid kit should be present.

An interesting example to meditate on: a photo taken in a pumping station in Morocco.

It is a mirror, which reminds us that each has the primary responsibility for its own security (even
visitors!)

Figure 2.1: Primary person for safety responsibility

2.3 Record activities, follow up and analysis

The Manager must ensure that all O&M activities are regularly recorded.
He must make at least quarterly inspection to ensure the consistency of the data reported then
records or register them for further analysis.
• It is important to review the books and records, to flush out clerical errors, and assess the
quality of attendant work.
• The analysis will first refer to the data in a summary table and graphs.
• These are graphics that allow analysis by interpreting trends curves that develop over the
quarters.
• Tables to calculate averages that can be compared to other pumping stations or gravitational
systems
Thorough checks and analyses to show that the staff is able to fill out the registers and records in a
proper way. This is a kind of motivation to perform well next time.

2.4 Responsibilities of the personnel

Responsibility of the technical manager:
• Organize the work and skills so that the assets of the RWSS operates on their normal life.
• To know in detail, the assets, their rules of operation and their maintenance needs.

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• Guiding and controlling staff.

• Provide staff with the appropriate hardware and tools.
• Establish contacts according the problem of spare parts.
• Prepare a sufficient annual budget for continuous and sustainable exploitation.
• Operate registers and records, make analysis, and present in the official forms.

Responsibility of Pump Attendant:

• Ensure O&M of the pumping station.
• Manage the stock fuel and lubricant.
• Place an order on time to avoid stock outs.
• Save the tools.
• Stay in place until the pump is running (unless all is running by electricity).
• Fill out all operating records or holding registers.
• Report any discrepancies to the technical manager.
• Involve the engineer designated by the Manager for any action beyond his level of
competence, or for which he does not have the appropriate tools.

Responsibility of the Guardian:

• Keep security and ensure the cleaning of the pumping station.
• Never leave the station without being relayed by another or by the pump attendant.
• Inform attendant or technical manager about any abnormal situation.

2.5 Tools
All workers must have on hand the following groups of tools:
• Manufacturer's documentation on the operation of assets.
• Operating forms to fill out, pens, binder or folder for storage.
• Means of communication if areas are isolated, such as mobile phone.
• Cleaning equipment.
• Access key to tanks, valves chambers, stock, etcetera.
• Tools to carry out the operation and maintenance; examples are shown in the Annex.

2.6 Spare Parts

Access to spare parts is a major problem for Operators.
This problem is aggravated by the wide variety of equipment installed by projects in the past and
the lack of (national) standardized guidelines.
The Operator can find the parts, if he has the money to pay a supplier, but it may take a long time
(time control, routing from abroad, customs clearance, delivery to station, and installation).
These realities must be anticipated because, unfortunately, all that is mechanical or electronic can
fail at any time.

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Some guidelines, therefore, are required:

• Require from the owner all documentation on the installed equipment:
Manufacturers ‘catalogues, contact addresses in the country, operation manuals,
maintenance manuals.
• Identify brands, types and numbers of equipment, local suppliers who can provide spare
parts, specialists in pumping equipment and measurements.
• Take advantage of the FEPEAR-Operators to locate other stations which have the same
equipment.
• With these contacts, build a list of prices to facilitate budgeting of maintenance and repairs.

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3 Lesson 3: Overview of Water Supply

3.1 Sources of water
There are basically three categories of naturally occurring water resources: Groundwater,
rainwater and surface water.

3.1.1 Groundwater
Part of the precipitation that falls infiltrates the soil. This water replenishes the soil moisture, or
is used by growing plants and returned to the atmosphere by transpiration.
Water that drains downward (percolates) below the root zone finally reaches a level at which all
the openings or voids in the earth's materials are filled with water. This zone is called the zone of
saturation. The water in the zone of saturation is called the ground water.
Groundwater occurs under most of the world's land surface, but there are great variations in the
depths at which it is found, it’s mineral quality, the quantities present and the rates of infiltration
(thus yield potential) and the nature of the ground above it (thus accessibility).
In hilly areas it emerges from the ground in places as natural springs, otherwise wells have to be
constructed and pumps or other lift mechanisms installed.
Springs:
• A spring is a visible outlet from a natural underground water system. Management and
protection of the whole system, including the unseen underground part, is essential if the
spring is to be used for water supply.
• The conservation of Wetlands or spring seepage areas is an extremely important and
integral part of spring water development and management.

3.1.2 Rainwater
Rainwater collection, from roofs or larger catchment areas, can be utilized as a source of
drinking water, particularly where there are no other safe water sources available, for example in
areas where groundwater is polluted or too deep to economically tap.

3.1.3 Surface Water

Surface Water, in streams, lakes and ponds is readily available in many populated areas, but it is
almost always polluted. It should only be used if there are no other safe sources of water available.
In general, a water supply system with surface water comprises the following processes:
• Raw water extraction and transport;
• Water treatment and storage;
• Clear water transport and distribution.

3.2 Types of distribution systems

With respect to the way the water is supplied, the following distribution systems can be
distinguished:

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• Gravity systems;
• Pumping systems.
The choice of one of the above alternatives is closely linked to the existing topographical
conditions.

3.2.1 Gravity systems

Gravity systems makes use of the existing topography. In this case the source is located at a
higher elevation than the distribution area itself.
The water distribution can take place without pumping and nevertheless under acceptable
pressure. The advantages of this system are:
• No energy costs;
• Simple operation: fewer mechanical components, no power supply needed;
• Low maintenance costs;
• Slower pressure changes.

3.2.2 Pumped systems

In pumped systems, the energy needed for water conveyance is obtained from the pump
operation.
This energy, generated by the pump impeller, is usually expressed as a head of water column and
is called the pumping head: it represents the difference between the energy levels at the pump
entrance at the suction pipe and at the discharge pipe.
Highly elevated reservoirs will usually be located at the downstream side of the pumping
station in order to be refilled during the periods of low demand.
The low-level reservoirs, on the other hand, will be positioned at the upstream side of the pumping
station

Apart from that, pumps can be located anywhere in the network where additional pressure is
required: these pumps are called booster pumps.
[Link] Direct pumping scheme
In the direct pumping scheme, the system operates without storage provision for demand
balancing.
The entire demand is directly pumped into the network. As the pumping schedule has to
follow variations in water demand, the proper selection of pumps is important in order to
optimize the energy consumption. Reserve pumping capacity for irregular situations should also
be planned.

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Figure 3.1: Direct pumping scheme

Advantages of the direct pumping scheme are opposite to those of the gravity scheme. With good
design and operation, any pressure in the system can be reached. However, these are systems with
rather complicated O&M, and they are dependent on a reliable energy supply. Additional
precautions are therefore necessary, such as an alternative source of energy supply, automatic mode
of pump operation, stock of spare parts, etc.

[Link] Indirect pumping scheme

Indirect pumping assumes an operation with pumping stations and require balancing reservoirs.
A considerable storage volume is needed in this case but pumping capacities will be below those
in the direct pumping scheme. The indirect systems are common in hilly distribution areas. Water
enters and exits out of the bottom of the reservoir.

Figure 3.2: Indirect pumping scheme

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4 Lesson 4: PUMPING STATION GENERAL

4.1 Description and background information
The major components inside the pumping station are pumps, motor (s), pipework, valves and a
range of pump monitoring and controlling devices. The pump itself includes an encased
impeller. The impeller is powered using a motor.
Water flows into the suction pipework, and flows out into the discharge pipework. There is often
additional infrastructure outside a pumping station building. This may include connecting pipework,
on site electrical transformer, cables, external pipe valves and water storage tanks.

In figure 4.1 an example is given of a pumping station in Rwanda. In the upper part of the
drawing the suction reservoir is shown and the drawing below two pumps, the water meter and the
anti-water hammer construction are schematized.

Figure 4.1: Equipment in pumping station Muyinga

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In figure 4.2 a detailed drawing of a pump is shown together with its connecting appendages.

Legend:
1. Entrance with Rounded Edge 5. Non-return Valve
2. Isolating Valve 6. Isolating Valve
3. Offset Conical Reducer 7. 90° Elbow (or short radius bend)
4. Concentric Conical Increaser 8. Tee Fitting.

Figure 4.2: Pump with connecting appendages

In figure 4.3 another example is given.

Figure 4.3: Pump with connection appendages

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Pumping station control

There are a range of devices inside the pumping station which assist in controlling how the
pumping station operates and how the flow and pressure of the water is managed. The pipework
has a number of isolation valves which allow segments to be switched off. Installed on the
discharge pipework, control valves control the water flow when the pumps are starting and
stopping. There is also a non‐return valve on the discharge pipework. It’s a simple gate valve
which shuts off water backflow into the pumping station, if needed. Some control devices are
listed in table 4.1 (suction side) and table 4.2 (discharge side).

Table 4.1: Suction side equipment

Equipment Description
Strainer or filter Prevent the introduction of coarse objects in the suction pipeline
Back foot check valve Prevent the water back into the reservoir located in the suction
line to facilitate priming.
Piping Made of metal pipes often assembled with flanges
Elbows Change the orientation of the pipe
Tee Facilitate removable lead
Decreasing cones Facilitate change of diameters of pipe to connect to the inlet pump
Shutoff valve Facilitate the interchangeability of pumps in operation.
Part disassembly Facilitate the dismantling of parts placed at each place where
you must disassemble for maintenance
Seals Soft rubber parts for easy sealing
Flanges Metal parts in the form of circular ring with standardized holes often
fixed by welding on the pipe fitting
Bolts Round and threaded metal parts to facilitate the clamping flange

Table 4.2: Discharge side equipment

Equipment Description
Motor Keep the pump running
Decreasing cones Facilitate change diameters of pipe to connect to inlet tubing of
the pump
Piping Made of metal pipes often assembled with flanges.
Elbows Change the orientation of the pipe
Air valve Lead the air out, at the high point with no straight pipe

Non-return valve Prevent the backflow of discharge pipe to the pump

Shut-off valve Facilitate flow control and if necessary in removing the pump
Part disassembly Facilitate dismantling parts
Gauge Indicate delivery height

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Equipment Description
Air vessel Dampen oscillations due to shock waves when stopping pump
Increasing cones Enlarge the diameter of the pipe
Discharge pipe Water transport to the discharge tank

Protection against water hammer

Water hammer is a phenomenon caused by the transient

(unsteady) flow of water in a pipeline. Water hammer is
important in pumping station design as it can cause the
rupture of pipe and pump casing, vibration, pipe collapse
and excessive displacement of pipes and fittings.
• When you close a faucet you sometimes hear a shock in
the pipe.
• In practice, the water hammer is a series high speed
wave due the overpressure and depression.
To prevent problems associated with transients in a system,
a number of alternatives can be investigated which include
the: Figure 4.4: Air vessel
• Selection of pipes and fittings to withstand the anticipated pressures
• Selection and location of control devices (air vessels, surge relief valves, air valves, etc.) to
alleviate the adverse effects of transients.
• Identification of appropriate pump start-up and shutdown procedures, as well as suitable
valve closure times.
Consulting firms can calculate the required volume of an air vessel to alleviate water hammer in
a system.

4.2 Operation
A pumping station is a very sensitive facility to be guarded and protected. No one can access
the perimeter of a pumping station, which must be closed:
• This is to protect the station (fragile material, valuable equipment, fuel reserve, tools);
• And also protect people (risk of fire, burn, cut).

A pumping station must be clean:

• It is a proof of professionalism and competence;
• It is a good prevention against overheating of the devices, and for tracking slight leakage
(oil, fuel, water).
Any incident at the station may have a detrimental effect on water service; contrary to the
obligation of the operator to ensure the continuity of public service.

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4.3 Preventive Maintenance

Most equipment on a pumping station needs preventive maintenance.
This maintenance can be well prepared on standardized schedules which should thoroughly
and accurately be filled in by the persons who carry out this kind of maintenance.
In table 4.3 and example is given of a schedule for preventive maintenance of a reservoir.

Table 4.3: Schedule of preventive maintenance

Subject Action Staff Frequency

• Check the appearance,

TANK • Check seals, clean if necessary.
outside • Check that there are no threatening erosions around
the facility.
• Fix what does not need a mason, otherwise report and
propose action.
METALIC • Check the condition of the closure, grease hinges,
COVER ON clean. Plumber/
THE TOP Quarterly
• If corrosion or need welding to report and propose Water
SLAB action. technician
VALVES: • Check the operation by pressing,
Inlet, Outlet, • Clean up all valves, fittings, unions etc..
By-pass
INLET • Check inlet, the operation of float (adjust if
Pipe, flow necessary)
limiter, float • Dismantle the coupling, clean up
valve
VENTILATIO Check air passage valves and sealing
N

4.4 Curative Maintenance

If any equipment is not functioning, it should be repaired.

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5 Lesson 5: PUMPS
5.1 All pumps
5.1.1 Description and background information
There are many types of pumps. These different types of pumps are grouped into two categories in
which the principles of operation are completely different:
• Turbine pumps like centrifugal pumps;
• Volumetric pumps like piston pump.

In the turbine pump, a wheel provided with blades and vanes, driven by a rotational movement
provides the fluid (water) to a kinetic energy which is converted into pressure by a reduction in speed
of member called recuperator (diffuser).

In the volumetric pumps instead the energy is provided by the successive variations of a volume
alternately connected to the suction port and the discharge port.

Adapted from GUYER (2012)

Volumetric pumps are not used in drinking water supply.
There are generally two types of turbine pumps used for potable water pumping applications:
• The vertical turbine pump (line shaft and submersible types);
• The centrifugal horizontal or vertical split case pump designed for water-works service.

Adapted from THE WORLD BANK RWSS (2012)

• If the suction level is less than 6 meters, use a centrifugal pump.
• If the suction level is from 6-20 meters, use a submersible.
• If the suction level greater than 20 meters, use a submersible or a turbine pump.

In figure 5.1 the three graphs of a pump are presented: the pump characteristics.

Figure 5.1: Pump characteristics

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 Training Module on O&M of Pumps in Rural Water Supply Systems

The curve flow – head (QH):

It presents the changes in the total head H by the pump as a function of the flow rate Q.
Curve is a parabola more or less diving.
The curve of power absorbed by the pump according to the flow is also parabolic. In centrifugal
pumps, the concavity of the curve is facing downwards. This helps to prevent motor overload if the
conditions are expected to vary. For propeller pump, it is better to avoid the discharge valve because
for zero flow there is a risk of surges when the pump is driven by an electrical motor.
The yield curve η represents the variations in performance (ratio of input power and output) of the
pump according to the flows: the curve for each type of pump should have a maximum in the vicinity
of the flow corresponding to the water demand.
Manufacturers give for each pump a graph according to the change of rotation speed, throughput,
power consumption, and the pressure. See figure 5.2.

Figure 5.2: different QH-curves

5.1.2 Operation
（1）The starting-up of the pump

 Case 1: The pump automatically starts and stops.

This requires a connection to the public power grid, an automatic pump and telemetry.
• Telemetry: system for monitoring and remote control the filling of the suction tank and
discharge tank, by electrical cable or wireless command.
• This is the safest position, provided that the quality of the grid current is well
controlled.
• There is no human intervention, except a daily monitoring visit by an unskilled agent.

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 Training Module on O&M of Pumps in Rural Water Supply Systems

• This does not apply to stations with generator.

 Case 2: The pump stops automatically; but manually starts:

The system is equipped with a pressure switch, which cuts off the electric current of the pump
when it reaches a predetermined pressure.
• This pressure is reached when the float valve of the reservoir closes (the reservoir is full,
the float rises and closes the flow, like a water flush of WC).
• To restart the pump, wait until the reservoir empties a little and manually restart.
• This system avoids the overflow on the reservoir, without the need for telemetry
(electricity and electronics) or a tank’s guard for monitoring and prevention purposes.

 Case 3: The pump starts and stops manually:

The system has no automatism.
• It needs a pump attendant at the station for the start. This allows checking everything
before the pump starts.
To stop:
• Either you put a watchman on the reservoir, who, by phone, will give the stop signal;
• Either the pump attendant has enough experience to know how long it must pump. But
it's pretty random because you never know the actual level of the reservoir at the start of
pumping;
• To improve the system, reservoirs normally include outdoor levels to monitor the filling.
In practice, it is extremely rare that they work properly.
Start-up operations:
• Check the cleanliness.
• Check the water level in the suction tank, and the absence of impurities.
• Check and adjust levels: oil and diesel fuel of diesel motor or EG.
• Check inventory, fill out the forms.
• Mark index of available devices on the record: water levels in reservoirs, water meters,
electric meters, pressure gauges, indexes schedules machines and the start time.
• Start EG. Let it run without load for 3 minutes to heat
• Check volts and Amperes dials (if any) and all indicator lights.
• Engage the pump.
• Monitor all lights and indicators. Attention should be paid to the sounds of machines.
Check that there are no leaks of fuel or water.

（2） During pumping operation time

• Except for fully automated stations, all others must have a guardian at all times
during pumping.
• This may be the station’s day or night guard, who has received specific instructions about
what to monitor and how he can stop pumping (emergency procedure).
• The Operator must be aware of the value of the pumping facilities, and his responsibility

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 Training Module on O&M of Pumps in Rural Water Supply Systems

for their life span.

（3）Pump stop procedure in normal situation

Under normal circumstances, stop pumping takes place more or less by taking reverse actions at
start up.
Normal stopping occurs when:
• The discharge tank is full;
• The suction tank is empty;
• Time is up for stopping machines.
Stop operations:
• Monitor all lights and indicators. Attention should be paid to the sounds of machines.
Check that there are no leaks of fuel or water and no overheating.
• Start pumping stopping procedure.
• If there is a EG, the pump should be stopped first and after that the EG.
• Record water meter reading, pressure gauges reading and stop time.
• Check stocks, whether they are sufficient for the next day.
• Check the cleanliness, clean the station and appliances.

（4）Pump stop procedure in emergency situation

The emergency stop should be a procedure in which attendants must be prepared in advance and
trained.
The emergency stop occurs when a wrong item is noticed: red light, heating, dials showing abnormal
data.
The emergency procedure should be defined case by case depending on the configuration of the
station.
• It will be written and displayed in the station.
• All personnel on the station will be trained on it twice a year. The following principles
should be applied to define the procedure:
• An Operator’s employee shall be permanently at the station while working.
• They need to know all the specific points that can trigger an emergency stop.
 Abnormal noise;
 Heating of device;
 Red lights;
 Loss of oil, fuel or water;
 Gauge that is not at it is routine pressure;
 Voltage or amperage that is not normal (heat up and burn the control box);
 Safety Issues: heavy rains, thunderstorm with lightning, suspicious people.

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 Training Module on O&M of Pumps in Rural Water Supply Systems

5.2 Centrifugal pump

5.2.1 Description and background information
A centrifugal pump is one of the simplest pieces of equipment in any process plant. Liquid is forced
into an impeller either by atmospheric pressure or in case of a jet pumps by artificial pressure.
The impeller vanes pass kinetic energy to the liquid, thereby causing the liquid to rotate. The liquid
leaves the impeller at high velocity. The impeller is surrounded by a volute casing or in case of a
turbine pumps a stationary diffuser ring. The volute or stationary diffuser ring converts the kinetic
energy into pressure energy.
In figure 5.3 two examples of centrifugal pumps are given.

Figure 5.3: examples of centrifugal pumps

5.2.2 Operation
To operate a centrifugal pump, certain procedures need to be followed, which are found in the
manual supplied by the manufacturer. They generally involve the following steps:
1. Before starting the motor, make sure that the discharge gate valve is closed.
2. If the pump is not self-priming or has defective suction line or foot valve, add priming water.
Priming displaces the air in the suction line of the pump with water.
3. Allow the pressure to build up, and then slowly open the discharge valve. Doing this slowly
avoid water hammer, which could destroy the pipes and valves.
4. Start the pump motor.
5. After the pressure has built up, slowly open the discharge gate valve. In case the pump has
been primed with water, waste the water pumped during the first 1-2 minutes by opening the
drain valve.
6. Make a routine check for faults in the operation of the system (abnormal noise, vibration,
heat, and odor).

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 Training Module on O&M of Pumps in Rural Water Supply Systems

5.2.3 Preventive maintenance

Bearings, gears and other pump moving parts should be lubricated on the regular schedules, using
the lubricants recommended by the supplier.

5.2.4 Curative maintenance

The following are specifications to remedy centrifugal pump problems.
[Link] Low Pump Efficiency
If the pump performance tests reveal that the pump is operating at significantly lowered efficiencies,
the pump should be pulled out, inspected and repaired or reconditioned. This work is best referred for
servicing to the manufacturer or a pump repair specialist.
[Link] Packing Adjustment
The water flowing through the stuffing box should be maintained at a level just enough to prevent
overheating. The gland nuts should be loosened or tightened one-quarter turn only to allow the
packing to equalize against the pressure.
[Link] Checking and Adjusting Misaligned Head Shaft
Pump vibrations could indicate a misalignment of the head shaft. This can be checked by the
following procedure:
• Remove the motor dust cover, motor head nut and key, and take out the motor drive
flange.
• Check if the head shaft is concentric with the motor hollow shaft bore.
• If needed, adjust by using shims.
Documentation from manufactures gives common problems and remedy as below for a centrifugal
pump: see table 5.1.

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Table 5.1: Common problems and remedy of centrifugal pump

5.3 Submersible pump

5.3.1 Description and background information
In figure 5.4, an example of a submersible pump is given.

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Figure 5.4: submersible pump

5.3.2 Operation
Submersible pumps may be operated manually with a switch located above ground level or
automatically with a pressure switch, electrodes or float control devices. Submersible pumps should
always be operated below the water level. The pump should be installed higher than the well screen
(a kind of filter) to prevent pump break on which will lead to a burned pump motor.

5.3.3 Preventive maintenance

To begin a maintenance job analysis, the assigned person needs the following information:
• Pump motor unit size and type;
• Static and pumping water level of the well;
• Size of drop pipe;
• Pump setting;
• Discharge pressure required;
• Capacity pumped;

5.3.4 Curative maintenance

Documentation from manufactures gives common problems and remedy as below for a
submersible pump: see table 5.2.

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 Training Module on O&M of Pumps in Rural Water Supply Systems

Table 5.2: Common problems and remedy for submersible pumps

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 Training Module on O&M of Pumps in Rural Water Supply Systems

5.4 Hand pump

5.4.1 Introduction
Most of handpump types are AFRIDEV or India Mark II in Rwanda. AFRIDEV pumps are used for
the boreholes which groundwater table is relatively shallow (0-20m). India Mark II pumps are used
for the boreholes which groundwater table is relatively deep (20-40m).

5.4.2 AFRIDEV Hand Pump

[Link] Pump parts and function
The assembly of the AFRIDEV pump is shown in the Figure 5.5. AFRIDEV pump parts are divided
into two categories “Above ground parts” shown in the Table 5.3 and “Below ground parts” shown
in the Table 5.4.

Figure 5.5: Assembly of AFRIDEV pump

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Table 5.3: Name and functions of each spare parts for above ground component

No. COMPONENT FUNCTION ILLUSTRATION

1 Head pump and cover Encloses the topmost part of the
pump to prevent dust and foreign
materials from getting inside the
pump, it houses the hanger
assembly and supports the handle
bar
2 Pump pedestal Main body supporting above
ground components and below
ground components

3 T/bar This is the part that is held to

pump water. It can be adjusted to
correspond to the depth of the
borehole

4 Hanger Assembly Rods are suspended from this

5 Fulcrum pin Joins the handle bar to the head

pump and acts as a movement
joint for the handle pumping water

6 Hanger pin Joins the end part of the handle to

the hanger to allow for upward
and downward movement of the
rods
7 Bush bearing Allows free movement of the
fulcrum pin and hanger pin. There
are four in a pump, two on the
fulcrum pin and two on the hanger
pin
8 Rubber flapper Installed on the top rod to prevent
foreign materials from getting into
the rising main and to prevent
water from gushing out

9 Rubber cone Sits between the pump head and

pedestal acts as a seal to stop
water from spilling between the
pump head and pedestal

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No. COMPONENT FUNCTION ILLUSTRATION

10 Steel cone plate A metal plate holding the rising
main

11 Top sleeve (collar) It prevents the rising main from

slipping through the rubber cone

Table 5.4: Name and functions of each spare parts for below ground component

No. COMPONENT FUNCTION ILLUSTRATION

1 Pump rod To connect plunger so that the
pump can be operated above the
ground using the handle

2 Rod centralizer / Fitted on rod joints to centralize

rods and prevent friction between
the rod and the rising main
3 Plunger Connected to pump rods; moves
up and down with the movement
of the handle to facilitate suction
of and delivery of water
4 Foot-valve Keeps the pumped water from
going back down the bore hole

5 U-seal Fitted to the plunger body; seals

water above plunger and pushes
water up with every upward
movement of the plunger
(plastic plunger only)
6 Cup-seal Fitted to the plunger body; seals
water above plunger and pushes
water up with every upward
movement of the plunger (brass
plunger only)
7 O-ring Fitted to the foot valve to prevent
water inside the
cylinder from getting back into
the bore hole
8 Bobbin Fitted inside plunger and foot
valve; moves up and down to
allow water to move in one
direction only and prevents water

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No. COMPONENT FUNCTION ILLUSTRATION

from getting back into the bore
hole
9 Rising main A pipe connected to cylinder
assembly carries water from the
cylinder to ground level
10 Double end socket To join two rising mains after
repairing (use solvent cement)
11 Solvent cement To join two rising mains after
repairing (use solvent cement)

12 Rising main centralizer Fitted every 3 meters, rising main

prevents excessive swaying of the
rising main in the borehole

13 Cylinder assembly Most important part of the pump,

it draws water from the borehole
and pumps it up to ground level
14 Suction pipe Fitted at the bottom end of the
cylinder it draws water into the
cylinder and controls sand intake
15 Rope (nylon rope 6mm) Connected to the suction pipe and
passes through the pipe centralizer
to the cone plate to hold the rising
main from falling into the
borehole in case of joint failure

[Link] Tools
Necessary tools for dismantling and reassembling AFRIDEV pump are shown in the Table 5.5.

Table 5.5: Tools for AFRIDEV pump

No. COMPONENT FUNCTION ILLUSTRATION

1 Socket spanner 24mm To remove head cover and to
hold the hanger assembly when
removing rods

2 Flat spanner17/19mm To remove the bolts between

head and pedestal

3 Fishing tool To fish the foot valve and pump

rods

[Link] Dismantling
Necessary steps for dismantling are described as Table 5.6.

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Table 5.6: Necessary steps for dismantling

No. Step Illustration No. Step Illustration

1 Before starting wash 2 Loosen the pump
your hands and fill head cover bolt
some buckets with
water to allow you to
clean the parts

3 Take off the cover 4 Loosen both hanger

nuts

5 Loosen both fulcrum 6 Put spanner through

nuts hanger eye.

7 Raise and withdraw 8 Remove fulcrum pin

handle. Take care! and bush bearings.
As you remove the
handle make sure
that the bush
bearings and pin do
not fall out as they
may break on the
floor.
9 Place all parts in the 10 Remove hanger pin
cover for safe and bush bearings.
keeping.

11 Pull up the hanger 12 Slide up the rubber

and first rod. centralizer where the
rods join.

13 Disconnect and 14 Remove the plunger.

remove all the
rods. Remember to
keep the rods in the
same order.
The last rod taken
out should be the
first one put back.

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No. Step Illustration No. Step Illustration

15 Lower the fishing 16 Gently lower last rod
tool and join to the and hanger until you
rods. feel that you have
caught the foot
valve.

17 Remove all the rods, 18 Push out the bobbin

fishing tool and foot from the foot valve
valve. with your thumb. If
the bobbin is
damaged replace it
with a new one.

19 Remove the O- ring 20 Push out the bobbin

from the foot valve. from the plunger
If the O- ring is with your thumb. If
damaged replace it the bobbin is
with a new one. damaged replace it
with a new one.

21 Carefully remove the

U-seal. If the U-seal
is damaged replace it
with a new one.
Make sure that the
groove faces
upwards.
Source: Training Manual for Area Mechanics, Ministry of Agriculture, Irrigation and Water Development,
Government of Malawi, March 2015

[Link] Reassembling
Necessary steps for reassembling are shown in the Table 5.7.

Table 5.7: Necessary steps for reassembling

No. Step Illustration No. Step Illustration

1 Wash the foot valve, 2 To re-assemble the
plunger and rods. pump first drop the
Only use clean water. foot valve down the
borehole. Make sure
the hook is upwards.

3 Put the plunger and 4 Make sure the rubber

pump rods back centralizer is slide
together and lower down over each joint
them down the on the pump rods.
borehole.

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No. Step Illustration No. Step Illustration

5 Join all the rods 6 Make sure the foot
together until the valve is in place by
hanger rod is pushing the rods at
connected. arm length down the
borehole.

7 Put the spanner 8 Turn the hanger pin

through the hanger and bush bearings so
eye to support the that the small
rods and then projecting lugs are at
replace the hanger the top.
pin and bush
bearings. If the bush
bearings are worn
out or damaged then
replace them with
new ones.
9 Put back the fulcrum 10 Put back the handle.
pin and bush
bearings in the
handle. If the bush
bearings are worn
out or damaged then
replace them with
new ones.
11 Make sure the 12 Tighten the fulcrum
projection lugs on nuts by hand.
the pin and bush
bearings will fit into
slots on the pump
body.
Ensure that the pin is
pushed right to the
back of the slot.
13 Push the handle 14 Tighten the hanger
down so that the nuts with the
slots engage in the spanner
hanger. Ensure that alternatively on both
the hanger pin has sides.
slid to the
bottom of the slots.
Remove the spanner.
15 Tighten the 16 Put back the cover.
fulcrum nuts with
the spanner
alternatively on both
sides.

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 Training Module on O&M of Pumps in Rural Water Supply Systems

No. Step Illustration No. Step Illustration

17 Tighten the cover 18 Pump water until
nut. clean water comes
out before using for
drinking.

Source: Training Manual for Area Mechanics, Ministry of Agriculture, Irrigation and Water Development,
Government of Malawi, March 2015

[Link] Curative Maintenance

[Link].1 Trouble shooting

Identify problems at the water point. Possible problems and remedies are outlined as follows.
1) No water?
2) Delayed flow of water?
3) Reduced discharge water?
4) Water is turbid?
5) Taste is salty? or water smells?
6) Abnormal noise during operation?
7) Pump handle is shaky?

Table 5.8: Trouble shooting chart for AFRIDEV pump

Problem Possible case Remedy Degree of

repairs*
1
1) No water 1) Riser pipes are 1) Pull out complete rising main and B
disconnected repair/replace pipes
2) Pump rods are disconnected 2) Pull out pump rods and replace A
broken and corroded rods
3) Cap seal is defective 3) Replace cap seal A
4) Borehole is clogged (silt or 4) Rehabilitation of boreholes C
sand)
5) Water level has dropped 5) Add riser pipes and pump rods B
under the cylinder
2) Delayed 6) Leaking of valve bobbins 6) Check and replace bobbins (plunger A
discharge and foot valve)
water 7) Leaking of foot valve O- 7) Replace O-ring A
ring
8) Leaking in pipe joint or 8) Pull out complete rising main and B
rising main is perforated repair/replace pipes
3) Reduced 9) Cup seal is too tight 9) Replace with seal of correct size A
discharge 10) Borehole screen is 10) Rehabilitation of borehole (cleaning C
water clogged by incrustation with compressed air or by bailing)
11) Full stroke is not possible 11) Check and adjust length of the top rod B
12) Cup seal is worn 12) Replace seal A
13) Leaking of valve bobbins 13) Check and replace bobbins (plunger A
and foot valve)

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Problem Possible case Remedy Degree of

repairs*
1
14) Leaking of cylinder 14) Pull out complete rising main and B
(cracked) repair/replace cylinder (solvent cement
joint)
4) Water is 15) Accumulation by 15) Rehabilitation of borehole (cleaning C
turbid siltation becomes large with compressed air or by bailing)
16) Screen/casing pipes are 16) Rehabilitation of borehole (relining C
torn casing/screen pipes inside existing casing
pipes, if possible)
5) Taste is 17) Sewage intrusion through 17) Rehabilitation of platform C
salty or water cracks of platform/apron
smells 18) Contamination through 18) Check the distance from the pit
aquifer pathway latrine and abandon the pit latrine within a A
radius of 100 m of the
borehole
6) Abnormal 19) Bearings are worn, 19) Check and replace bearing sets (4 pcs) A
noise during handle fork touching the
operation sides
20) Pump rods are touching 20) Straighten or replace bent pump rods A
riser and replace worn rods
21) Pump rods rubbing on 21) Check and replace worn pump rod A
riser pipes centralizers
22) Pump rod centralizers 22) Check and straighten bent pump rods A
worn and replace worn rods
7) Pump 23) Pump platform i s cracked 23) Repair pump platform C
handle is 24) Flanges are loose 24) Tighten all bolts and nuts of the A
shaky flanges
25) Bearings are worn 25) Check and replace bearing sets (4 pcs) A
26) Fulcrum pin is loose 26) Check fulcrum pin (and bearing sets) A
and tighten both nuts fully
27) Hanger pin is loose 27) Check hanger pin (and bearing sets) A
and tighten both nuts fully
*1 Degree of repair;
A: Caretaker (s) of Water Users Committee (WUC) can repair
B: It is recommended to ask professional technician (s) to repair (highlighted by grey color in above table)
C: It is recommended to ask District (s) to repair

（1）Identify fast wearing parts and their effects in pump operation

It is cheaper to replace the fast wearing parts than to allow effects of the worn parts to damage more
expensive parts. Fast wearing parts are as follows.
Spare parts for handle
• Bush bearing
• Spare pump rod
• Rod centralizer
Spare parts for cylinder
• U-seal (cup-seal)

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• O-ring
• Bobbin

（2）Identification of problems in the rising main

Possible reasons of problems of the rising main are as follows;

• Leakage at joints due to poor practice when making joints
• Perforations made on pipe due to rubbing with rods or worn out centralizers
• Cracks in pipe

（3）Repairing rising main

The rising main will need to be removed if;

• There is excessive leakage that cannot be attributed to a leaking foot valve bobbin or “O”
ring.
• Items have been dropped or have jammed inside the rising main that cannot be fished out.
• The cylinder is suspected of needing replacement.
• The riser pipes are disconnected.
Traditionally when the rising main was removed it was cut into manageable lengths, a maximum of
2 lengths (6m), which meant that a large number of joints had to be re-made upon replacement. In
addition, suitable double sockets were not available and joints were formed by warming the PVC
pipes in a fire. It is very important that joints in the PVC rising main are correctly made to ensure a
sustainable long-term repair.
To minimize the number of joints that need to be made during a repair the rising main is removed
from the borehole in one length without making any cuts. The problem is identified and repaired
before replacing the rising main back in the borehole, once again in one length.
During removal of the rising main in one length the joints will come under considerable stress.
This procedure should only be attempted if it is known that the uPVC joints were correctly made in
accordance with “6.3.2 Making joints” during the installation. Otherwise there is a danger that a joint
may break and could cause injury.
In addition to the tools needed for pump repair the additional resources needed to withdraw the rising
main are:
• At least 8 people, preferably including all or some of the pump caretakers.
• It is recommended that more people should be available.
• Poles with forked ends and the number should be equal to the number of rising mains in
the installation. Four should be 3.5m long and the rest should be 4m long.
• A guide rope at least 10m long
A cleared area long enough to accommodate the rising main so that it may be laid down without delay
after withdrawal.

1）Removing and replacing of rising main

The procedure is shown in the below Table 5.9.

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Table 5.9: Procedure for removing and replacement of rising main

Step Activity Note / Photo

1 Remove the foot valve. This may not be possible if there are components
stuck inside the rising main. It is still possible to
remove the rising main in one piece but extra care
must be taken as the weight of water and
components will make the control of the rising
main as it comes out of the borehole much more
difficult.
2 Remove the pump head As shown in the Table 5.6
3 Tie the guide rope to the cone plate.

4 Start to pull the rising main of the borehole The support rope should have knots made on both
by pulling the two ends of the support rope sides to coincide with the top of the rising main
and the pipe. The guide rope is used to pipe before pulling out the rising main.
control the free end of the pipe These marks can be used to check if the rising
main length has been changed during repairs.
5 As the rising main comes out of t he The direction might be chosen considering where
borehole start to bend it in the d irection there is space.
chosen for it to be laid down. Using the
short forked poles start to take the weight
of the pipes at the same time keeping the
radius of the bend as long as possible.

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 Training Module on O&M of Pumps in Rural Water Supply Systems

Step Activity Note / Photo

6 As the pipe is pulled out the longer forked There is a minimum of one forked stick per length
poles are used to support the free end of the of rising main. The radius of curvature is kept as
pipe which should be kept up and the pipe long as possible. The section of pipe already
horizontal so that the bend is at least three extracted, on the left in the photo below, is kept
pipes long. If it has not been possible to horizontal and curvature is spread over at least
remove the foot valve, the open end of the three pipe lengths. Additional support is given to
pipe should be lowered just enough to the pipes being bent. Leaking and broken parts
drain the water out so that the weight is should be marked as the rising main is being
reduced. The shorter poles at the borehole removed.
end of the pipe need to be held off the
ground to allow them to be moved easily
along the line of removal. The longer
poles in the middle and the free end can
be allowed to rest on the ground to take
the weight and stabilize the pipe.

7 If at any time a joint appears to be weak (e.g.

there is evidence of burning as in a
homemade joint) the pipe should be carefully
supported and cut at the suspect joint. Do not -
try to bend a weak joint.
8 When the cylinder and suction pipe are Select a suitable place to lay down the pipes and
reached they are carefully withdrawn, carefully examine the rising main for damage and
making sure to maintain control of the whole signs of leaking
pipe. The whole pipe length can now be laid
down.
9 After the necessary repairs have been carried
out the whole length of pipe must be
carefully cleaned before replacement. Before
replacing the pipe the borehole should be
sterilized using at least 250 grams of high
test hypochlorite (HTH). At the very least all -
down hole components must be thoroughly
cleaned.
10 The pipe is then replaced in the reverse When the cylinder and suction pipe are ready, they
procedure of removal. Some difficulty may are carefully inserted into the borehole, making sure
be experienced inserting the cylinder and to maintain control of the whole pipe.
suction pipe, as some force has to be applied
to bend the pipe sufficiently to insert it into
the borehole.

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2）Repairing of rising main

Unless an obstruction can be removed by tipping the pipe up, which is very unlikely, or there is
leakage from a joint that can be reconnected, it will be necessary to cut the rising main.
The choice of where to cut depends upon the repair that needs to be carried out. If there is a hole in
the pipe, which may be caused by the internal rubbing of a rod joint because rod centralizers have not
been replaced when worn, the pipe will need to be cut in two places one on each side of the hole. If
the problem only requires access to the inside of the rising main or cylinder, such as the removal of
an obstruction, then the pipe only needs to be cut in one place. The location of the cut depends upon
the problem to be resolved.
The overall length of the rising main must not be changed. It is very important that the timing of the
pump is not changed, i.e., the lengths of the pipes and of the rods are not changed.
All joints must be made using a “Double Socket”. A Double Socket is a straight piece of pipe 230
mm long with an internal diameter that just fits over the outside of the rising main pipe. Each end of
the pipe at the joint must be marked at 115 mm to ensure that the double socket is equally distributed
over the joint. The joining of PVC pipe should be done in accordance with “Making joints on rising
main”.
If a length of pipe has had to be cut out, for example if it has a hole in it, it must be replaced by a pipe
of equal length and two double socket joints made. The shortest length of a repair should be 300mm
to ensure that the joints on each side are adequate. Do not be tempted to make a patch with a piece of
pipe and stick it on using solvent cement. It will not last and the rod centraliser will be quickly
damaged as it rubs past the inside of the hole.

Figure 5.6: Typical pipe repairing method

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3）Making joints on rising main

◆ Tools and materials
Before making joints on the rising main the tools and materials mentioned below should be
prepared:
• A hacksaw with spare blades
• A measuring tape and marker
• Solvent cement
• Cleaning fluid
• File
• Sand paper
• Cloth
◆ Making joints
The procedure is shown in the Table 5.10.

Table 5.10: Procedure for making joints

Step Activity Note / Photo

1 Mark the depth of the socket (115
mm) on the plain end of the pipe. If
the mark is removed during cleaning
the pipe centralizer can be located at
the correct place as a depth gauge.

2 The outer edge of the plain end should

be bevelled at 15o to 20o(if not
already done at the factory).

3 If a pipe has had to be cut on site

during a repair the inner edge of the
plain end should also be smoothed -
and all burrs removed, otherwise the
plunger and foot valve may be difficult
to remove. In the case of a plunger with
a cup seal it may prove impossible to
remove all of the burrs
4 Clean the pipe (bell end inside and
plain end up to 115mm) with cloth

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Step Activity Note / Photo

and cleaning fluid (Carbon tetra
chloride).

5 Roughen the cleaned surfaces with

sandpaper.

6 Clean again with cleaning fluid. -

7 Apply solvent cement up to the mark Care must be taken not to apply too much solvent
on the outside of the plain end and on cement which could weaken the pipe wall by
the inside of the bell end of the rising dissolving it. Also a bead of excess dissolved
main with a brush. Replace the caps uPVC on the inside of the joint may interfere with
tightly on the cleaning fluid and the the plunger and rod centralizers.
solvent cement after each use.
8 Insert the plain end into the bell end
of the other pipe as quickly as
possible. Do not twist or rotate the
pipe during insertion. Push hard to -
make sure that the plain end enters
the full length to the mark (or the
centralizer).
9 Wipe off any excess solvent cement
with a cloth. -
10 Allow to set for at least five minutes.
The nylon rope should be anchored
during these five minutes. -
11 Check the mark and ascertain how far -
the plain end entered.
12 Lower the pipe into the borehole
using the nylon rope. -
13 Allow pipes to cure for about 24
hours before applying any pressure, -
i.e., do not use the pump.

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[Link] Preventive maintenance

[Link].1 Identification of problems

This section is re-edited based on “Installation and Maintenance Manual for the AFRIDEV Hand
pump, Revision 2-2007, SKAT-RWSN”.
Problems may be identified during regular preventive maintenance and it will be necessary to
diagnose the faults and determine the possible reasons for them. Preventive maintenance means
regular check-up of the hand pump at a fixed time interval (weekly or monthly) and changing of spare
parts before they are fully worn.
Such interventions help in preventing the sudden failure of the pump.

（1）Weekly checks

Weekly check shall be conducted in accordance with the Table 5.11.

Table 5.11: Weekly checks

No. Item Illustration

1 Check that the flange bolts and nuts
are tight.

2 Check that the fulcrum pin and

hanger pin nuts are tight.

（2）Monthly checks

Monthly check shall be conducted in accordance with the Table 5.12.

Table 5.12: Monthly checks

No. Item Illustration

1 Check if any fasteners or parts in
the pump head are missing. If so,
replace the parts.

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No. Item Illustration

2 If any unusual noise is noticed,

check reason for the same and take
corrective actions.

3
Check if the pump stand is shaky
during operation. If yes, the stand is
loose in the foundation and
contamination of the well can take
place. Take corrective measures to
repair the foundation.

4 Carry out a “Leakage Test” as

detailed below.
5 Carry out a “Discharge Test” as
detailed below.

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1）Leakage test
Leakage test proceed as follows.
Start

Operate pump handle until water is

flowing from the spout.

Stop operating the pump handle for

approximately 30 minutes.

Operate the handle and count exactly

how many strokes are required until the
water is starting to flow again

No (less than 5 handle strokes)

If more than 5 handle
strokes are required to Acceptable
make the water flow

Yes (more than 5 handle strokes)

There must be a leakage in the rising main or the foot valve and cause should be
investigated.

Leakage mostly occurs because of;

a. worn bobbin or O-ring of the foot valve
b. disconnected rising main joints or perforated

Source: Installation and Maintenance Manual for the AFRIDEV Handpump, Revision 2- 2007, SKAT-RWSN

Figure 5.7: Flowchart of leakage test

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2）Discharge test
Discharge test proceed as follows.

Start

Operate pump handle until a

constant water flow is achieved.
(pump ratio approximately 40 full
handle strokes per minute)

Place a bucket in the continuous

water flow for exactly one minute.

Take the bucket off the water flow

and check the amount of water

No (more than 10 liters)

If discharge is
less than 10 liters Acceptable

Yes (less than 10 liters)

There might be a problem with the bobbins or the cup seal.

Source: Installation and Maintenance Manual for the AFRIDEV Handpump, Revision 2- 2007, SKAT-RWSN

Figure 5.8: Flowchart of discharge test

[Link].2 Records
Any repairs must be recorded in the Water Users Committees (WUCs) record book. Full details of
repairs must be entered such as;
• Date of repairs
• Nature of problem(s) encountered
• Cost of parts replaced
• Cost of labour
• Who carried out the repairs?

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5.4.3 India Mark II hand Pump

[Link] Pump parts and function
India Mark II pump parts are divided into two categories “Above ground parts” and “Below ground
parts”. Assembly of India Mark II pump is shown in the Figure 5.9 and India Mark II pump cylinder
is shown in the Figure 5.10.

Figure 5.9: Assembly of India Mark II pump

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Figure 5.10: India Mark II pump cylinder

[Link] Tools
The India Mark II has two kinds of tool kits; the Standard tool kit and the Special tool kit. These tools
are shown in the Figure 5.11.

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 Training Module on O&M of Pumps in Rural Water Supply Systems

Standard tool kit Special tool kit

Figure 5.11: India Mark II tools

[Link].1 Standard tools

Standard tools for India Mark II pump are listed in the Table 5.13 and shown in the Figure 5.12.

Table 5.13: Standard tools for India Mark II

No. Tools Qty

1 Button Die (to suit 12mm rod) M 12 x 1.75mm Threads 1 set
2 Die set for 32mm GI pipe 1 set
3 600mm pipe wrench 1 no.
4 450mm pipe wrench 1 no.
5 300mm pipe wrench 1 no.
6 M17 x M19 double ended spanners (to suit 10mm x 12mm bolts & nuts) 2 nos.
7 300mm adjustable spanner 1 no.
8 Screw driver 300mm long 1 no.
9 Screw driver 150mm long 1 no.
10 1kg ball pein hammer with handle 1 no.
11 Hacksaw frame with two spare blades 300mm 1 no.
12 Pressure type oil can (1/2 pint with oil) 1 no.
13 Wire brush 1 no.
14 250mm half round file with handle 1 no.
15 250mm flat file with handle 1 no.
16 Lithium base / multipurpose grease 1 kg
17 Graphite Grease 1 kg
18 Nylon rope (3mm thick) 75 m

Button Die Die set

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Pipe wrench Double ended spanners

Screw driver Ball pein hammer

Hacksaw Wire brush

Flat file with handle Multipurpose grease

Figure 5.12: Standard tools for India Mark II

[Link].2 Special tools

The special tools for India Mark II pumps as shown in the Figure 5.13 and should be used for the
repair technician while dismantling, reassembling or repairing.

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1. SELF LOCKING CLAMP

2. TANK PIPE LIFTER
3. COUPLING SPANNER
4. HANDLE AXLE PUNCH
5. CONNECTING ROD LIFTER
6. CRANK SPANNER
7. LIFTING SPANNER
8. CONNECTING ROD VICE
9. CHAIN COUPLER SUPPORTING TOOL
10. BEARING PRESSING TOOL
11. TOOL BOX

Figure 5.13: Special tools for India Mark II

Tools Description
Tool No.1: Use this tool for holding rising main while lifting or lowering. While raising the
pipe, you need not operate the handle to open out the jaws, as the tool has been
Self-locking Clamp
devised to facilitate pulling out the rising main couplers without opening of the
jaws by hand.
Tool No.2: Use this tool to lower or lift the water tank with rising main.
Tank pipe lifter 1. Screw it on to water tank coupling
2. Use 2 or 3 lifting spanners equally spaced on the tank pipe lifter to raise or
lower water tank assembly.
Tool No.3: Use this tool for tightening the connecting rod coupler faster and with ease.
Coupling Spanner
Tool No.4: This tool is used for driving out the handle axle without damage to axle threads
Handle Axle Punch (A) For driving out the handle axle, the sequence should be:
1. Remove axle nuts and washers
2. Put handle axle punch on taper portion of axle
3. Hammer gently handles axle punch until you are able to pull out axle by hand.
(B) While driving the handle axle, the sequence should be as under:
1. Insert the handle axle punch through left bush and bearings
2. Insert the handle axle through right bush so that threaded portion goes into the
handle axle punch

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Tools Description
3. Hold the handle axle punch by one hand hammer gently the handle axle.
4. Hammer the handle axle till the handle axle threaded portion comes out through
left bush. The handle axle punch would have come out by then.
Tool No.5: Use this tool for raising or lowering the connecting rod.
Connecting Rod 1. Thread on the tool to the connecting rod
Lifter
2. Insert lifting spanner
3. Lift or lower as required
Tool No.6: Use crank spanners for tightening or loosening flange bolts. Check nuts, nylon nuts
and anchor bolts.
Crank Spanner
Tool No.7: Use this tool to raise or lower rising main. These lifting spanners are suitable for
32mm (1 1/4 inch) pipes.
Lifting Spanner
1. Lifting spanners should be spaced equally around the rising main.
2. Use two lifting spanners to lower or lift up to 30m of rising main.
3. Use three lifting spanners if the rising main is longer than 30m. Do not use pipe,
wrenches for lifting or lowering the rising main.
4. You can also use one lifting spanner to lock the pipe with the help of a pipe
wrench.
Tool No.8: Use this tool for holding the connecting rod, while connecting rod is cut and
threaded.
Connecting Rod
vice
Tool No.9: Place this tool between the chain coupler and the flange of conversion head
assembly. This facilitates easy fixing of chain on to the handle assembly as the
Chain coupler
entire rod weight is supported by this tool.
supporting tool

[Link] Dismantling
Necessary steps for dismantling are described as follows:

[Link].1 Above ground component

Necessary steps for dismantling above ground component are described in the Table 5.14.

Table 5.14: Necessary steps of dismantling above ground component

No. Step Illustration No. Step Illustration

1 Loosen pump head 2 Remove pump head
cover bolt. cover.

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No. Step Illustration No. Step Illustration

3 Lower pump handle. 4 Lift up the pump
Put chain supporting handle to top
support below the position. Use two
chain assembly. open-ended spanners
to loosen “Nyloc”
nut.

5 Remove the “Nyloc” 6 Loosen and remove

nut anchor bolt and bolts and nuts
pull out chain from connecting head and
the handle. water tank.

7 Lift and remove head 8 Turn flange 90º. Lift

assembly. The chain connecting rod by
will go through hole holding middle flange
in the bottom flange. and insert connecting
rod vice.

9 Place rods vice on 10 Unscrew check nut

water tank top flange and remove middle
and tighten it. Leave flange.
the middle flange
resting on the rod
vice. Take off the
chain support and
loosen and remove
the chain assembly
from top rod.
11 Attach the rod lifter 12 Gently lower the
(in clockwise pump rod assembly
direction). Hold the until it sits on top of
rod lifter firmly, open the check valve.
the vice and remove Unscrew the rod
it. lifter.

13 Remove all bolts 14 Lift the water tank up

between water tank wards (about 50 cm)
and pump stand. and introduce and
fasten pipe vice.

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No. Step Illustration No. Step Illustration

15 Unscrew water tank
by turning the spout
by hand.

[Link].2 Below ground component

The below ground components of the India Mark II pump can be dismantled (and re-installed) with
two different systems.
1）For pump installations between 10 to 30 m, the rising main pipe with pump rods and the cylinder
can be lifted with 2 or 3 specially designed Lifting spanners. Therefore, a short piece of a threaded
riser pipe can be connected to the thread of the water tank, so that the Lifting spanners can be applied.
2）For pump installations between 30 to 50 m, the weight of the below ground components is
increasing and therefore a Tripod with a Chain block (or pulley wheel with rope) can be used for
lifting the rising main pipe with pump rods and cylinder.
For getting a secure grip on the rising main, a pipe clamp needs to be attached and a piece of rope is
used to attach the pipe with pipe clamp to the hook of the lifting device (chain block).
After lifting the below ground components for a complete pipe length (3 m), a Pipe vice is used to fix
the riser pipe in position when the retrieved riser pipe and the pump rod are getting unscrewed.

Lifting spanners Tripod with chain block

Pipe clamp Pipe vice

Figure 5.14: Lifting devise

The Table 5.15 shows the necessary steps of dismantling the below ground components with a tripod
& chain block.

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Table 5.15: Necessary steps of dismantling below ground component

No. Step Illustration

1 Attach pipe clamp and connect it with a piece of
rope to the hook of the chain block.
2 Operate chain block until the chain is tight and then
open the pipe vice slowly and remove it.
3 Lift rising main pipe, pump rods and cylinder until
the next pipe socket is about 0.5 m above the top
flange of pump stand.
4 Introduce the pipe vice and clamp the rising main
securely.
5 Remove the pipe clamp and open the protruding
riser pipe with two pipe wrenches.

6 Lift the unscrewed riser pipe by hand, so that the

pump rod connection is visible.
7 Unscrew the pump rod connection and place the
rods and pipes separately on a clean place.
8 Attach pipe clamp to the remaining rising main
pipe (close to the pipe vice).
9 Connect pipe clamp to the hook of the chain block
and tighten the chain.
10 Continue with Step 1 to Step 9 until the whole
rising main, pump rods and cylinder are retrieved.

Please note: For shallow dismantling an

installations where the total weight of the rising
main, pump rods and cylinder is not so heavy,
dismantling (and also re-installation) of the below
ground components can be done easily with the
Lifting spanners.

11 The last riser pipe can then be removed from the

cylinder.

12 Then the last pump rod gets disconnected from the

plunger rod.

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No. Step Illustration

13 From the cylinders, both caps can be opened and
the plunger & check valve removed.
14 The plunger and the check valve can also be
dismantled to check or replace worn parts (cup seal
and rubber seating).
15 Once the defective pump components have been
replaced and the pump is re-assembled again,
explanations needs to be given to the pump users
about the diagnostic (what the problem was and
why the break down might has happened).

[Link] Reassembling

[Link].1 Preparation
Necessary steps for preparation for reassembling are described in the Table 5.16.
（1）Below ground component
1） Riser pipes and pump rods

Table 5.16: Necessary steps of preparation of riser pipes and pump rods

No. Step Illustration

1 Check all pipe threads with socket for good
engagement,
2 Check all pump rod threads with couplers for good
engagement,
3 Apply hemp fiber with grease or sealing liquid to one
threaded end of all pipes and attach one socket,
4 Place a number of logs or a pipe stand near the
installation place,
5 Place all prepared pipes neatly on top of the logs or
pipe stand (above the ground) so that all threads
remain clean,
6 Introduce one pump rod to each of the riser pipes and
make sure that the long hexagonal couplers are on the
same side as the riser pipe sockets.

2）Pump cylinder（From Step1 to Step4）

Table 5.17: Step1: Assemble all components of the plunger

No. Step Illustration No. Step Illustration

1 Place Rubber seating 2 Attach a Cup seal to the
to the Upper valve lower part of the
Spacer

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No. Step Illustration No. Step Illustration

3 Attach a Cup seal to the 4 Attach another Cup
lower part of the seal at the top of the
Spacer Spacer

5 Introduce the follower 6 Introduce the follower

into the spacer and into the spacer and
place the upper valve place the upper valve
on top of the assembly on top of the assembly

7 Attach Plunger body 8 Take Plunger rod and

and tighten securely tighten it to the Plunger
assembly

9 Take Plunger rod and

tighten it to the Plunger
assembly

Table 5.18: Step 2: Assemble all components of the check valve body

No. Step Illustration No. Step Illustration

1 Assemble Check 2 Place rubber seating
valve with Check and secure with seat
valve seat retainer

3 Place rubber seating

and secure with seat
retainer

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Table 5.19: Step3: Assemble the pump cylinder

No. Step Illustration No. Step Illustration

1 Prior to assembling check cleanliness of 2 Place first sealing
cylinder liner and clean all threads and ring into a reducer
prepare them with sealing fluid or hemp cap
fiber with grease (cylinder pipe and
Reducer caps).

3 Introduce Check 4 Attach the cylinder

valve and place with liner to the
second sealing ring Reducer cap

5 Introduce plunger 6 Place third sealing

assembly into the ring and attach
cylinder pipe reducer cap

7 Tighten both reducer

caps with pipe
wrenches

Table 5.20: Step 4: Leakage test

No. Step Illustration

1 Immerse suction part of cylinder into a bucket with clean water.
Operate the plunger by pulling and pushing the plunger rod.

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No. Step Illustration

2 As soon as the cylinder is filled, place it in a vertical position and
check for any leaks.
Be aware that a small amount of water is dripping from the outer
surface of the cylinder.
Wait therefore for some minutes until the cylinder surface is dry, not
to assume any dripping water automatically as leakage.
If there is any leakage, try to tighten both reducer caps, before
dismantling the cylinder for finding the reason of the leakage.
Once the cylinder is water tight, the installation of the “down hole
components” can start.

（2）Above ground component（From Step1 to Step2）

1）Assembling of pump handle

Table 5.21: Step1: Assembling pump handle

No. Step Illustration No. Step Illustration

1 Place first ball 2 Introduce mounting
bearing to bearing tool into bearing
mounting tool housing

3 Insert spacer into 4 Place second ball

bearing housing bearing on bearing
mounting tool

5 Introduce pressure 6 Add the hexagonal

plate on bearing nut
mounting tool

7 Take two spanners

(19 mm) and tighten
the nut of the bearing
mounting tool, so that
both ball bearings are
pushed into their end
position. If ball
bearings are mounted,
remove bearing
mounting tool.

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2）Assembling of pump head

Table 5.22: Step 2: Assembling of pump head

No. Step Illustration No. Step Illustration

1 Introduce the pre- 2 Knock the handle
assembled pump axle gently into the
handle into the pump end position (use a
head assembly and plastic hammer if
place the ball available).
bearings near the axle
bushes at the sides of
the Pump head.

3 Introduce axle washer 4 If the pump handle is

and fasten one nut by moving smoothly
hand. (up- & down), take
second nut as a check
nut to secure the
correct position.

5 If the pump handle is

moving smoothly
(up- & down), take
second nut as a check
nut to secure the
correct position.

[Link].2 Below ground component

Table 5.23: Necessary steps of reassembling below ground component

No. Step Illustration No. Step Illustration

1 Take the first riser 2 If the pump rod is
pipe with pump rod tight, apply hemp
from the logs. Place it fibers with grease,
horizontally on the sealing liquid or
pump platform and Teflon tape to the
connect the pump rod pipe thread and screw
to the plunger rod of the riser pipe into the
the cylinder. reducer cap of the
cylinder.

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No. Step Illustration No. Step Illustration

3 Tighten riser pipe 4 Lower the first riser
with reducer cap of pipe with cylinder
the cylinder with two into the pump stand
pipe wrenches. (by hand) until the
riser pipe protrudes
the top face of the
pump stand by
approx. 50 cm.

5 Introduce the pipe 6 Take the second riser

vice and fasten the pipe with pump rod
riser pipe in this from the logs,
position (ideal connect the pump
working height) rods first and then the
riser pipe after hemp
fibers with grease,
sealing liquid or
Teflon tape has been
applied.

7 With the help of the 8 Proceed in the same

two lifting spanners, manner until the last
the rising main can be pump rod and riser
lowered after the pipe pipe is connected.
vice has been opened
and removed.

Please note: As soon as the rising main is 9 At the end of the last
too heavy for being handled with the lifting riser pipe located in
spanners (5 to 10 pipe lengths), attach the the pipe vice, the
pipe clamp and connect it with the hook of water tank will be
the chain block. Lower the rising main with attached. Therefore
the help of the chain block on the tripod take off the last
until the height required (50 cm) for the socket of the last riser
next connection is reached! pipe and re-apply
hemp fibers with
grease or sealing
liquid to the pipe
thread.

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No. Step Illustration No. Step Illustration

10 Then the water tank 11a (For shallow
is screwed on to the installations, when
last pipe end and rising main is not
tighten by hand. heavy). With the help
of a short piece of
riser pipe attached to
the socket in the
water tank, the entire
rising main can be
held in place with the
help of 2 or 3 lifting
spanners. As soon as
the pipe vice has
been removed, the
riser pipe assembly
with water tank can
be lowered slowly to
the pump stand
flange.
11b (For deep 12 Turn the water tank
installations with so that the spout is
heavy rising main pointing into the
assemblies). With a required direction
short piece of rope and tighten it
attached to the hook properly to the pump
of the chain block, stand with 4 x M12
the water tank can be bolts and nuts. Now
held securely in the installation of the
position, so that the “above ground
pipe vice can be components” can
removed from the start.
pump stand. Then the
water tank with rising
main attached can be
slowly lowered to the
pump stand flange.

[Link].3 Above ground component

Table 5.24: Necessary steps of reassembling above ground component

No. Step Illustration No. Step Illustration

1 The protruding last 2 Use a hacksaw for
pump rod needs to be marking the exact
cut to the exact length of the last
length, so that the pump rod (at the top
plunger connected is face of the water tank
not knocking the flange).
check valve or the
cylinder cap during
pump operation.

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No. Step Illustration No. Step Illustration

3 Lift marked pump rod 4 Cut last pump rod at
for easy cutting and the mark.
fasten with
connecting rod vice
on the top flange of
the water tank. Take a
clean piece of cloth
and wrap it around
the marked rod, in
order to prevent metal
shavings or oil from
falling into the well
(contamination).
5 Remove sharp edges 6 Use little oil for
and make a nice cutting the M12
chamfer prior to thread (40 mm long).
threading. As soon as thread is
finished, remove
cloth carefully and
clean pump rod, vice
and pump stand from
remaining oil and
shavings. Prevent
shavings from falling
into well.
7 Insert middle flange. 8 Allow middle flange
to rest on top of
connecting rod vice
and fix the check nut
on the newly
threaded top rod.

9 Screw the chain 10 Tighten check nut of

coupler on the connecting rod with
connecting rod the chain coupler.
threads by hand

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 Training Module on O&M of Pumps in Rural Water Supply Systems

No. Step Illustration No. Step Illustration

11 Insert chain coupler 12 Carefully lower the
supporting tool below middle flange to the
the chain coupler. top of water tank and
Hold middle flange ensure that all four
and remove corners coincide.
connecting rod vice.

13 Hold head assembly 14 Tighten head, middle

in position and insert flange and water tank
chain through the with bolts and nuts.
hole in the
bottom/flange.
Lower head on top of
middle flange
ensuring all four
corners to coincide.

15 Lift handle up and 16 Tighten “Nyloc” nut.

attach free end of the
chain with high
tensile bolt, washer
and “Nyloc” nut.

17 Lower the handle and 18 Lift handle up and

remove chain coupler apply grease on the
supporting tool. chain.

19 Make sure: that the connecting rod moves 20 Fit inspection cover.
up and down freely. If it does not, the rod
has been bent. Check the rod,
that the chain coupler is fully engaged on
the connecting rod and that the lock nut is
tight, that the axle nut and lock nut on the
handle are tight, that the handle axle is firm
in place, that the “Nyloc” nut has been
tightened securely with the chain anchor
bolt, that all 8 flange bolts and nuts are
tight, that nothing has been left inside the
pump head (tools, cloth etc.).

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No. Step Illustration No. Step Illustration

21 Tighten the cover 22 Now the hand pump must be operated for
bolt. first filling of the rising main pipe.
Depending on the depth of the cylinder
setting, the pump handle has to be operated
for many strokes (as an example: a 40 m
cylinder setting requires approx. 100 full
handle strokes for filling the entire rising
main).

23 As soon as the water is flowing from the 24 If the water quality is

spout, operate the pump for another 100 full acceptable
strokes. Check whether the water is clean (optically), the
(no oil or dirt). If the water is not clean, the leakage test and the
pump operation needs to be continued until discharge test must
the water is acceptable. be made (see f. i. ii
and iii).

[Link] Curative Maintenance

[Link].1 Trouble shooting

Below is a table illustrating the common causes and their respective remedies for the India Mark II.

Table 5.25: Trouble shooting chart for India Mark II pump

Trouble Possible Causes Remedy Who

Pump works Worn cup-seals Pull out rising main, open cylinder and Pump
easily, but no flow replace all worn cup-seals mechanic
of water Water level dropped below Add more riser pipes and pump rods Pump
cylinder mechanic
Broken chain Replace chain Pump users
Check valve jammed (not Pull out rising main, open cylinder, check Pump
closing) function of check valve and make needed mechanic
replacements
Pump rod disconnected Pull out rising main and join disconnected Pump
pump rod mechanic
Delayed flow or Check valve leaking Pull out rising main, open cylinder, check Pump
little flow of water leaking of check valve and make mechanic
replacements if required
Worn sealing rings Pull out rising main, check sealing rings Pump
and make replacements if needed mechanic
Worn cup-seals Pull out rising main, open cylinder and Pump
replace all worn cup-seals mechanic
Damaged rising main Pull out rising main, check all riser pipes Pump
(leaking pipe threads or and make replacements if required mechanic
severe pipe corrosion)
Folding of chain Plunger jammed inside Pull out rising main, open cylinder, check Pump
during down- cylinder size of plunger and cylinder and replace mechanic
stroke wrong or defective components
Top rod too long, plunger is Take off pump head, check correct length Pump
sitting on top of the check of pump rod assembly and trace top rod if mechanic

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Trouble Possible Causes Remedy Who

valve needed
Noise during Lack of grease on chain Grease chain Pump user
pump operation Worn ball bearings Replace ball bearings Pump
mechanic
Shaky foundation Check foundation and make necessary Pump
repair mechanic
Shaky pump Loose handle axle nuts Tighten handle axle nuts
handle Worn or damaged spacer Replace spacer
Worn or damaged axle Replace handle axle Pump
mechanic
Worn ball bearings Replace ball bearings Pump
mechanic
Bearings loose in bearing Replace handle assembly (for possible Pump
house repair) mechanic

[Link].2 Identify fast wearing parts and their effects in pump operation
It is cheaper to replace the fast wearing parts than to allow effects of the worn parts to damage more
expensive parts. Fast wearing parts are as follows.
（1）Spare for pump head
• Hexagonal bolt for pump head and water tank M12 x 1.75 x 40mm long
• Hexagonal nut for pump head, water tank and handle axe M12 x 1.75mm
• High tensile bolt for chain assembly M10 x 1.5 x 40mm long
• “Nyloc” nut for chain assembly M10 x 1.5mm
• Handle axle (stainless steel)
• Washer for handle axle 4mm thick
• Ball bearing (No.620422)
• Spacer for handle axe
• Chain with coupling
• Bolt for front cover M12 x 1.75 x 20mm long
（2）Spare for riser pipes and pump rods
• Riser pipe socket 32mm ND medium grade hot dip galvanized
• Hexagonal coupling for connecting pump rod M12 x 1.75 x 50mm
（3）Spare for cylinder
• Leather cup washer
• Leather sealing ring
• Rubber seating (big)
• Rubber seating (small)

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[Link] Preventive maintenance

[Link].1 Identification of problems

This section is re-edited based on “Installation and Maintenance Manual for the India Mark II
Handpump, Edition 2008, SKAT-RWSN”.
The India Mark II hand pump is to be properly maintained to ensure safe potable drinking water
supply. Maintenance will prevent breakdowns and ensure continuous working of the hand pump.
India Mark II hand pump is like any other mechanical machine. Any machine should be kept clean,
if for no other reason than that in cleaning all parts are inspected for formation of rust, insufficient
lubrication, loose, bolts, nuts, etc., and also for missing parts in time to prevent major failures.
The following schedule of maintenance has been drawn at fixed intervals.
（1）Monthly
• Tighten the handle axle nut and lock nut
• Look for loose or missing flange bolts and nuts
• Open the front cover, clean inside the pump
• Check the chain anchor bolt for proper fitment
• Tighten, if necessary
• Clean the chain assembly. Apply graphite grease
• Look for rusty patches. If seen, the same may be cleaned with the help of wire brush/ sand
paper and apply anti-corrosive paint
• Find out whether the hand pump is loose at the base. If it is loose, arrange for fresh
foundation to be constructed.
（2）Yearly
1）Examine the hand pump carefully and check whether:
• Discharge is satisfactory
• Handle is shaky
• Guide bush is excessively worn out
• All bolts, nuts and washers are in position
• Chain has worn out
• Roller chain guide is excessively worn out
2）Pull out the hand pump and follow the instruction given below: -
• If chain, bearing and spacer are damaged, replace them
• If roller chain guide is badly worn out replace handle assembly
• If any pipes are damaged replace them
• Open out cylinder assembly and replace cup washers, sealing rings and also any other part
found defective
• Check the condition of water tank riser pipe holder. If threads are worn out, replace water
chamber.
• Check all sub-assemblies for crack in weld and other visual defects. If defects are serious
replace sub-assemblies

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• Reinstall the hand pump as per instructions given in the manual. Paint the pump head
inside/ outside with the recommended color after cleaning/ sanding the surfaces.

[Link].2 Leakage test

Testing shall start after a continuous flow of water through the spout has been obtained. The water
shall then be collected in a container or bucket for 40 continuous full strokes of the plunger in one
minute. Measure the quantity of water collected. Then allow the pump to rest for 30 minutes.
Repeat the test and measure the discharge. The difference between the first and the second reading of
discharge indicates leakage. If the difference is more than 2 litres, there is an un- acceptable leak and
the cause should be investigated.
Another method is to count the number of strokes required before water comes out of the spout after
stopping operation for 30 minutes. If the number exceeds 5 strokes until water is flowing, it is an
indication that there is an un-acceptable leak and the cause should be investigated.
Leakage mostly occurs because of worn rubber components in the cylinder, leaking rising main joints
or severely corroded riser pipes.

[Link].3 Discharge test

Testing shall start after a continuous flow of water through the spout has been obtained. The water
shall then be collected in a container or bucket for 40 continuous full strokes of the plunger in
approximately one minute. The water collected should be generally not less than 16 litres.
If the discharge is less than 10 litres for 40 strokes, the repair technician needs to be called for pulling
out the rising main pipe and dismantling the cylinder for detecting the reason of the leakage.
Another cause for a low discharge could be a perforated or cracked riser pipe due to severe corrosion
or a non-tight riser pipe joint.

[Link].4 Records
Any repairs must be recorded in the Water Users Committees (WUCs) record book. Full details of
repairs must be entered such as;
• Nature of problem (s) encountered
• Cost of parts replaced
• Cost of labour
• Who carried out the repairs

5.4.4 Disinfection
Method of disinfection is shown in the “Cleaning and Disinfecting Wells, Technical Notes on
Drinking Water, Sanitation and Hygiene for Emergency Cases” by WEDC, World Health
Organization (WHO).
[Link] Disinfection of the borehole
WHO endorses the disinfection of drinking-water in emergency situations. There are various ways of
doing this but the most common is chlorination as it leaves a residual disinfectant in the water after
chlorination.
Chlorine has the advantage of being widely available, simple to measure and use, and it dissolves
easily in water. Its disadvantages are that it is a hazardous substance (to be stored and handled with
care) and that at commonly applied concentrations it is not effective against all pathogens (e.g. cysts

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and viruses, which require higher chlorine concentrations).

The chlorine compound most commonly used is high strength calcium hypochlorite (HSCH) in
powder or granular form which contains 60-80% chlorine. Also used is sodium hypochlorite in liquid
bleach or bleaching powder form. Each chlorine compound has a different amount of usable chlorine
depending on the quantity of time the product has been stored or exposed to the atmosphere and the
way it is made.
Figure 5.14 outlines methods for calculating appropriate chlorine doses for HSCH granule chlorine.
HSCH and bleach give off chlorine gas which is a serious health hazard.

Figure 5.14: Methods for calculating appropriate chlorine doses (source: Cleaning and
Disinfecting Wells, Technical Notes on Drinking Water, Sanitation and Hygiene for
Emergency Cases: WEDC, WHO).

[Link] Dewatering of the borehole

Following the minimum 30 minutes of contact period, remove water in the borehole using a hand
pump until the bad smell in the water will be disappeared. If there is a bad smell, do not use the water
for any purpose.
The following issues need extra care when dewatering boreholes:
1) The water will have a strong concentration of chlorine that will give it a bad taste and smell and
could be dangerous for human beings, animals, fishes, plants and other creatures.
2) Do not allow anyone to use the water in the borehole during the disinfection and dewatering
process.
3) Water with high concentration of chlorine should not flow into streams or wetlands.

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4) Remaining sediments or powders of HSCH in the bucket shall be buried in the ground of secure
place.
5) If the material of borehole casing is steel, chlorine causes corrosion. Contact period shall be
minimized and dewatering shall be done immediately.

5.5 Turbo pump

5.5.1 Description and background information
In fact, Turbo pumps is a term used to name a grouped components made by pump and pelton turbine,
the last provide required power by using falling water to make a turbine rotate to drive the pump,
depending on the source of the energy used. Turbo pumps are little used because of its low yield: it
only delivers about 30% of water used as energy source.
The repression height is limited by the allowable pressure of the materials of the pump and repression
pipes, but turbo pumps have also advantages:
• No need of other power source because water is used as energy source;
• Mechanical simplicity;
• Less maintenance;
• Relative long life-span comparing to other pumps.

Figure 5.11: Example of a turbo pump

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Figure 5.12: Nyamabuye II/ Gicumbi turbopump

5.6 Hydraulic ram

5.6.1 Description and background information
[Link] General
The hydraulic ram needs no external source of power. The ram utilizes the energy contained in a flow
of water running through it, to lift a small volume of this water to a higher level. The phenomenon
involved is that of a pressure surge, which develops when a moving mass of water is suddenly stopped.
A steady and reliable supply of water is required with a fall sufficient to operate the hydraulic ram.
Favorable conditions are mostly found in mountainous areas.

Figure 5.13: Hydraulic ram

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[Link] Principle
The ram operates on a flow of water running from the source down through the drive pipe into the
pump chamber. The water escapes through the opened impulse valve. When the flow of water through
the impulse valve is fast enough, the upward force on the valve will exceed the spring tension of the
valve adjustment and the impulse valve is suddenly shut.
The moving mass of water is stopped, with its momentum producing a pressure surge along the drive
pipe. Due to the pressure surge, water is forced through the non-return (delivery) valve and into the
delivery pipe.
Water continues to pass the non-return valve until the energy of the pressure surge in the drive pipe
is exhausted. The air chamber serves to smooth out the delivery flow of water, as it absorbs part of
the pressure surge that is released after the initial pressure wave.

impulse valve

non-return
delivery valve

Figure 5.14: principle of a hydraulic ram

When the pressure surge is fully exhausted, a slight suction created by the momentum of the water
flow, together with the weight of the water in the delivery pipe, shuts the non-return delivery
valve and prevents the water from running back into the pump chamber.
The adjustment spring now opens the impulse valve, water begins to escape through it, and a new
operating cycle is started.
Once the adjustment of the impulse valve has been set, the hydraulic ram needs no attention
provided the water flow from the supply source is continuous at an adequate rate and no foreign
matter gets into the pump, blocking the valves.
An air valve is provided to allow a certain amount of air to bleed in and keep the air chamber charged.
Water under pressure will absorb air and without a suitable air valve the air chamber would soon be
full of water. The hydraulic ram would cease to function.

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[Link] Advantages
• No power sources are needed, and therefore no running costs.
• Suitable for local production.
• Only two moving parts.
[Link] Preconditions
Most hydraulic rams will work at their best efficiency if the supply head is about one third of the
delivery head. The higher the pumping head required, the smaller the amount of water delivered.
In cases where the required pumping capacity is greater than one hydraulic ram can provide, a battery
of several rams may be used, provided the supply source is of sufficient capacity.

5.6.2 Operation
In fact, the water ram is self-operating and needs no human intervention.

5.6.3 Preventive maintenance

It is essential that as little debris as possible enters the drive pipe. For this reason, it is necessary to
provide a grate or strainer to keep back floating leaves and debris.

5.6.4 Curative maintenance

The maintenance required for a hydraulic ram is very little and infrequent. It includes activities as
replacement of the valve rubbers when they wear out, adjusting the tuning, and tightening bolts
if they get loose. Occasionally the hydraulic ram may need dismantling for cleaning.

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6 Lesson 6: POWER DRIVERS

6.1 Power supply
The energy needed for water conveyance is obtained from the pump operation. This energy, generated
by the pump impeller, is usually expressed as a head of water column (in mwc) and is called the
pumping head, hp. It represents the difference between the energy levels at the pump entrance i.e. at
the suction pipe and at the pump exit.
In the case of a single pump unit, the higher the pumping head hp is, the smaller the pumped flow Q
will be. For a combination of Q-hp values, the power P required to lift the water is calculated as:
P = ρ . g . hp . Q
The power Pp (or Np) to drive the pump will be higher, due to energy losses in the pump:

Where ɳp is the pump efficiency dependant on the pump model and working regime. Finally, the
power Pm (or Nm) required for the pump motor will be:

Where ɳm indicates the motor efficiency.

The above information is very crucial in pump selection, manufacturer provide all necessary
information to indicate the equipment characteristics.

6.2 Diesel Engine

6.2.1 Description and background information
Diesel engines have the important advantage that they can operate independently at remote sites. The
principal requirement is a supply of fuel and lubricants and these, once obtained, can be easily
transported to almost any location. Diesel engines, because of their ability to run independently of
electrical power supplies, are especially suitable for driving isolated pumping units such as raw
water intake pumps.
Diesel engines may be used to drive reciprocating plunger pumps as well as centrifugal pumps.
Gearing or another suitable transmission connects the engine with the pump. For any diesel-
driven pump installation, it is generally prudent to select an engine with 25-30 % surplus power to
allow for a possible heavier duty than under normal conditions.

6.2.2 Preventive maintenance

In almost all cases, diesel engine prime movers are designed as standby units, these must be given
proper care to prolong their life and for their efficient operation. In the absence of the equipment
operating manual, listed below are suggested preventive maintenance practices.

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◆ Every Third Day:

Operate the diesel engine at about 1,000 rpm for at least 5 minutes or until warm. This would allow
the lubricant and coolant to circulate around the engine.

◆ Every 8 hours Operation:

Check coolant level, sump oil level, oil reservoirs, for oil, water or fuel leaks and clean oil bath cleaner.

◆ Every 200 hours of Operation:

• Drain and renew engine lubricating oil.
• Renew lubricating oil canisters.
• Check tension of drive belt.
• Clean fuel water trap.
• Lubricate dynamo rear brush.
• Clean air filter element

◆ Every 400 hours of Operation:

• Renew fuel and air filter elements.
• Check hoses and clips.
• Clean lift pumps sediment chamber.

◆ Every 2,400 Hours of Operation:

• Check and adjust valve clearances.
• Service injector units.

6.3 Electrical Engine

6.3.1 Description and background information
Electric motors generally need less maintenance and are more reliable than diesel engines. They are
therefore preferable as a source of power for pumping, if a reliable supply of electric power is available.
The electric motor should be capable of carrying the workload that will be imposed, taking into
consideration the various adverse operating conditions under which the pump has to work. If the
power requirement of a pump exceeds the safe operating load of the electric motor, the motor may be
damaged or burnt out. Attention must also be paid to the characteristics of the motor and the supply
voltage.
There is sometimes a tendency to use general-purpose motors offered by the manufacturers
without giving due consideration to the characteristics of the particular pump used. This results in
frequent failure or burning out of the motor. The squirrel-cage motor is mostly selected for driving a
centrifugal pump as it is the simplest electric motor manufactured.

6.3.2 Preventive maintenance

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The most important items for good maintenance of an electric motor, aside from checking for bearing
wear, are regular use, and keeping it warm (from operation), clean, and dry. Moisture is an enemy of
insulation along with oil and dust.
Every motor should be operated for 5-6 hours at least every week. The longest useful life of a
motor is obtained from a unit which is never shut down and cooled off, especially in a humid
climate. Listed below are some maintenance tips.

◆ Every Day:
• Check temperature of motor housing with hand.
• Check lubrication reservoir level.
• Check air vents for blockage.
• Check external wiring for frayed insulation or loose connections.
• Check voltage and current at each leg of the three phases.

◆ Every Month:
• Check motor housing temperature.
• Check shaft alignment.
• Check input horsepower under load.

◆ Every Year:
• Vacuum all dust out of windings and motor case.
• Drain lubricant, flush out oil reservoir with kerosene, and replace with factory-approved
lubricant.

◆ Every Three Years:

• Examine winding insulation for damage.
• Clean oil connectors and contact points with fine emery cloth.
• Inspect shaft and bearings for scour, wear or damage.
• Check input horsepower under load.

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7 Lesson 7: SOURCES OF ENERGY

7.1 Diesel
The fuel diesel is a source of energy for a diesel engine of for an EG.

7.2 Electrical Grid

Electrical energy can just be taken out of a 24 hours functioning electrical grid.

7.3 Electrical Generator

If the electrical grid is not available or not functioning electrical energy can be taken from an EG which
uses diesel fuel.

7.4 Solar Power

Solar panels made of photovoltaic cells arranged into array convert sunlight into a direct current (DC).
This current is used to drive a (submersible) pump of the DC type. Another option is that the DC is
first converted to alternating current (AC) as most (submersible) pumps on the market are of the AC
type. On the other hand, converting DC means a substantial loss of energy (about 25 %). In
photovoltaic pumping systems, the pump works whenever there is adequate sunshine, and this is
independent of the ambient temperature.
The water is pumped into a storage tank to cater for water demands during the periods that there is
no sunlight and therefore no pumping. Solar powered pumps can lift water up to 100-200 m, but the
system is most economical up to a pumping head of 50 m.
The solar powered pumping system is an attractive option for remote areas where power and fuel
supply is difficult and expensive. The only requirement is sufficient sunlight. The investment cost is
high due to the (still) high price of solar panels, but O&M costs are low. Though the solar system is
vulnerable to vandalism and theft because solar panels have many applications.

7.5 Hydopower
Water which is fallen from a higher point is the energy source for a turbine pump.

7.6 Human Power

Using human power for pumping water with hand pumps has important benefits for small
communities in developing countries:
• The power requirements can be met from within the users’ group.
• The capital cost is generally low.
• The discharge capacity of one or more manual pumping devices is usually adequate to
meet the domestic water requirements of a small community, including, if needed, for
small-scale commercial use within households.

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• Design developments during the last 20 years mean that pumps can be repaired and
maintained by appropriately trained local caretakers.
The power available from human muscle depends on the individual, the environment and the duration
of the task. For work of long duration, for example eight hours per day, a healthy man is estimated to
produce 60-75 watts (0.08-0.10 horsepower). This value must be reduced for women, children and the
aged. It also must be reduced for high temperature and high humidity. Where the pump user and the
pump are poorly matched, much of the power input is wasted, for example, when a person operates a
pump from a stooped position. Tests and user evaluations help to bring out problems, such as rejection
of foot pumps because pregnant women and young children could not easily operate them or the
movement was not culturally acceptable.

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REFERENCES

WSP modules: 2.3 Opération et Maintenance des systèmes d’AEP ruraux et and 2.4 Opération et
Maintenance des stations de pompages rurales; Philippe Casterman

JICA modules: O&M Guidelines for water services providers; October 2013; JICA

PEPAS modules 3 and 4: TRAINING OF PRIVATE OPERATORS, DISTRICT AGENTS AND

WATER SUPPLY USERS IN HUYE, NYARUGURU AND GISAGARA DISTRICTS;
COFORWA

Public Water Corporation: Tech Guide—Hand Pump Equipped Boreholes; April 2009;
UNICEF

Hand pump: AFRIDEV_MANUAL

Power point from EWSA/PWN training: M2-O&M for pumps; October 2013; Paul Libaudière and
Theo de Veer

Pumps and pumping stations (collection «Rural Technology in Africa"); SOGREAH

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ANNEXES

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Annex I: water meters at a pumping station

Water meters measure the amount of water repressed. A water meter type used to measure high
flow rates is the Woltman type. It can be used for flow rates higher than 15 m³/h. They are thereby
distinguished by ensuring an especially low head loss, even with high flow rates. The newly
developed measuring insert with a special construction of the turbine where the water flows through,
guarantees a high measuring accuracy and long-term stability of the measuring results.

Main characteristics of Woltman water meter

Installation of Woltman meters

The best measuring results can be achieved if some simple but important installation rules are
followed.
• Woltman meters must be operated in the correct flow direction.
• There must be a minimum of 3 x DN of straight pipe section for WPH type upstream of
the meter (from Tee to water meter).
• There must be a minimum of 5 x DN of straight pipe section for WS type upstream of
the meter (from elbow to).
• If a sufficient straight pipe section is not possible, then a honeycomb flow straightener
should be installed.
• Ideally a straight pipe section of at least 2 x DN is present downstream of the meter.
• To avoid air pockets in the meter, it should not be installed on the highest point of the
piping.
• Gate valves or other shut-off valves in front of the meter should be completely opened
during operation.

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Annex II: Hydraulical background information

（1）Some fundamental laws
Force
Force = any action tending to change the status of a body

Intensity Unit of force: Newton

Application
point
Application point 4 elements of force

Pressure
• Pressure = Force / surface.
• The pressure is measured with a manometer.
• The unit of pressure is the [mwc]
• Scientists use the Pascal Pa = N/m2
• Correspondence of units: 1 bar = 1kg/cm2 = 105 Pa = 1MPa = 100 kPa = 10 mwc.

Force and Pressure

Assuming constant equal pressure, the degree of force is proportionally related to the pipe
section.
• F(N) = p [Pa] x A [m2]

Flow
The flow rate is the volume of water in m3 that passes per second
• Q=Axv
• v = velocity [m/s].

Power
• Power = work done by a force in a unit of time.
• 1 kW = 1,36 Horse Power

Head pressure
The pressure required to enable a column of water to reach a reservoir through pumping is:

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• Manometric Height = Δ z + (I x ℓ) [mwc]

• Δ z = The topographic level, difference between the starting level of the water body and
the level of the reservoir.
• I = loss of pressure per meter of repression [mwc/m]; Complex calculation by using
specialized software or graphical charts.
• ℓ = length of the discharge pipe [m]

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（2）Hydraulic Definitions

Discharge (Q): Also termed capacity or flow rate, is the volume of liquid pumped per unit of
time. Usually measured in SI units of m3/s, though for small pumps either l/s or m3/hr often
used.
Reference level: The reference level is defined as the elevation from the horizontal plane that
passes through the pump ‘eye’.
Operating Point of a pump Intersection flow and discharge head point in a system flow-
height curve.
Allowable Operating Range: A manufacturer’s recommended flow range for a pump of
specified speed and impeller diameter. The range is limited by cavitation (heating, vibration,
noise, shaft deflection, tiredness and other related criteria)
Total Static Head (Hst): The difference in elevation between the water level in the suction
well and the water level at the discharge reservoir.
Static Suction Head (hs). The difference in elevation between suction well water level and
the reference level.
Static Discharge Head (hd). The difference in elevation between discharge water level and
the reference level.
Manometric Suction Head (hgs). The suction gauge reading as measured at the suction
nozzle of a pump and is referenced to the reference level
Manometric Discharge Head (hgd). The discharge gauge reading as measured at the discharge
nozzle of a pump and is referenced to the reference level
Manometric head (Hg). The increase in pressure head generated by the pump (hgd– hgs).
Friction Headloss (hfs, hfd). The head of water that must be supplied to overcome frictional
resistance on the pipe wall.
Velocity Head (v2/2g). The kinetic energy of the pumped liquid at any point in system. The
Energy Gradeline (EGL) is always above the Hydraulic Gradeline (HGL) by v2/2g. HGL is
termed piezometric or manometric gradeline.
Minor Headlosses (hms, hmd): Each fitting type will result in a different minor head loss on
suction and discharge sides of pumps.
Total Dynamic Head (TDH): The total head at which a pump operates at any given discharge
rate. It is calculated by adding the total static head, the frictional headlosses, the velocity
heads, and the minor headlosses.

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（3）Required pressure at the discharge side of the pump

The pressure at the discharge side of the pump is composed of two components:
• Dynamic head
• Static head
Dynamic head covers the head-losses i.e. loss due to pipe resistance (hf) and loss due to fitting
resistance (hm). This component depends on the flow. The more flow, the more dynamic head.

The hf for one pipe can be calculated by the formula of Darcy-Weisbach.

hf = λ x ℓ / D x v2/2g
The hf is to the fifth power dependant from the D because the velocity v does also contain D.
The hf is quadractic related to the velocity (and indirectly to the flow Q).
To calculate the hf from a full distribution system you need the help of a computer.
The hm can be calculated with the help of tables.
In a distribution system the hf is far bigger comparing to the hm

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The static head is independent of the flow:

The static head includes:

• The required pressure at the end of the distribution system: pend
• Elevation difference Δz between the end of the distribution system and the location of the
pump

The pumping head required (hp) at the supply side of the system to maintain given pressure (pend) at
its end will be:
hp = ΔH+ + Δz

（4）Cavitation, vapor pressure and NPSH

The Net Positive Suction Head (NPSH) is the parameter used for risk analysis of cavitation. This
phenomenon occurs in situations when the pressure at the suction side of the pump drops below the
vapour pressure. As a result, fine air bubbles are formed indicating the water is boiling at room
temperature. When the water moves towards the area of high pressure, i.e. to the area around the
impeller, the bubbles suddenly collapse causing dynamic forces, ultimately resulting in pump erosion.

The damage becomes visible after the pump has been in operation for some time, and causes a
reduction of the pump capacity: the actual pumping curve shifts lower than the original one.

To understand Cavitation, you must first understand vapor pressure. Vapor pressure is the pressure
required to boil a liquid at a given temperature. Soda water is a good example of a high vapor
pressure liquid. Even at room temperature the carbon dioxide entrained in the soda is released. In a

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closed container, the soda is pressurized, keeping the vapor entrained.

Temperature affects vapor pressure. A chilled bottle of soda has a lower vapor pressure than a warm
bottle. Water, as another example, will not boil at room temperature since its vapor pressure is
lower than the surrounding atmospheric pressure. But, raise the water’s temperature 100°C and
the vapors are released because at that increased temperature the vapor pressure is greater than
the atmospheric pressure.
Pump cavitation occurs when the pressure in the pump inlet drops below the vapor pressure of the
liquid. Vapor bubbles form at the inlet of the pump and are moved to the discharge of the pump
where they collapse, often taking small pieces of the pump with them. Cavitation is often
characterized by:
• Loud noise often described as a grinding or “marbles” in the pump;
• Loss of capacity (bubbles are now taking up space where liquid should be);
• Pitting damage to parts as material is removed by the collapsing bubbles.

Noise is a nuisance and lower flows will slow your process, but pitting damage will ultimately
decrease the life of the pump. Often this is mistaken for corrosion, but unlike corrosion, the pitting
is isolated within the pump (corrosion attacks the pump material throughout).
No engineer wants to be responsible for installing a noisy, slow, damaged pump. It’s critical to get
the NPSH value from the pump manufacturer and to insure that your NPSH pressure will be
adequate to cover that requirement.
The NSPH Available (NPSHA) indicates how much the pump suction exceeds the liquid vapor
pressure, and is a characteristic of the system design. The NPSH Required (NPSHR) is the pump
suction needed to avoid cavitation, and is a characteristic of the pump design, to prevent cavitation.
The NPSHA has to be greater than the NPSHR.

The formula for calculating NPSHA:

NPSHA = HA ± HZ - HF + HV - HVP

Term Definition Notes

HA The absolute pressure on Typically, atmospheric pressure (vented supply tank), but
the surface of the liquid can be different for closed tanks.
in the supply tank • Don’t forget that altitude affects atmospheric
pressure (HA in Denver, CO will be lower than in Miami,
FL).
• Always positive (may be low, but even vacuum
vessels are at a positive absolute pressure)
HZ The vertical distance Can be positive when liquid level is above the centerline of the
between the surface of pump (called static head)
the liquid in the supply • Can be negative when liquid level is below the
tank and the centerline centerline of the pump (called suction lift)
of the pump
• Always be sure to use the lowest liquid level
ll d i th t k

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Term Definition Notes

HF Friction losses in the Piping and fittings act as a restriction, working against liquid as
suction piping it flows towards the pump inlet. HF come from the
calculation of the hydraulic head losses according to the
Darcy–Weisbach,
HV Velocity head at the Often not included as it’s normally quite small
pump suction port
HVP Absolute vapor pressure Must be subtracted in the end to make sure that the inlet
of the liquid at the pressure stays above the vapor pressure.
pumping temperature • Remember, as temperature goes up, so does the
vapor pressure

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Annex III: Tools

Maintenance tools
a) Flat key set from 6 to 32 mm
b) Set of key rings from 6 to 32 mm
c) Mixed key set from 6 to 32 mm
d) Socket wrench set from 6 to 32 + Accessories
e) 3 kg hammer with handle
f) Shears 24 "
g) Side cutting nippers
h) Adjustable self-locking plier
i) Screwdriver set flat and Phillips
j) Clipper
k) Set of adjustable wrenches
l) Complete set of chisels
m) Set of flat files
n) Set of round files

Mechanic tools
a) Set of needles
b) Pliers cutter
c) Hacksaw frame
d) Grease gun
e) Mallet
f) Key chain
g) Assortment of chromes-steel taps and dies
h) Hard pulley
i) Drill machine 720W-220V
j) Grinding machine 2200w – 220V
k) Engineering vice
l) Water pump (5m3 /hour to 15m H)

m) Riveting machine

n) Hand drill

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Electrician tools
a) 2 kg hammer
b) Cutting nippers
c) Electrician + spare blade knife
d) Pliers cutter
e) Strippers pliers
f) Socket wrench set for electrician + Accessories
g) Complete set of pliers
h) Detector current
i) Hacksaw frame
j) Hexagon key wrenches set
k) Multi meter to DC and AC digital
l) Soldering iron
m) Clip ampere meter
n) Glasses for welding
o) Solder mask

Plumbing tools
a) Hammer 2 kg
b) Adjustable self-locking plier
c) Set of adjustable wrenches
d) Side cutter plier
e) Pipe cutter
f) Pipe threading machine
g) Pipe wrenches
h) End cutting nippers
i) Hacksaw frame
j) Spirit levels
k) Square
l) Chain pipe wrenches
m) Pipe wrenches
n) Pipe fixing device

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Annex IV: Site exercise

Practical details depend on the configuration of the selected stations. It is up to the trainer to adapt to
circumstances.
The following activities will be conducted on site:
• Identify the elements.
• Read the plates and instructions.
• Draw a diagram of the station.
• Perform routine operations.
• Perform emergency operations.
All these activities will be conducted on site at a pumping station.
This sequence is scheduled in 3 hours by which one hour is to draw and finalize a station diagram,
another hour for an exercise to establish O&M plan adapted to existing equipment.
The practice of routine operations requires the presence of an electromechanical engineer accepted
by the operator and the owner in any case the trainer and the participants cannot handle the practice
themselves.

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