PVC Water Pumps 1

P V C WAT E R

PUMPS


By: Joseph
Longenecker

September 2010

Whats Inside:
Pump Design

Manufacturing Process I NTRODUCTION

Pump Performance The purpose of this document is to show several

water pump designs constructed from PVC pipe,
Appendix explain how to manufacture them, and discuss
pump performance and how to improve on these
designs.

Copyright ECHO 2007. All rights reserved. This document may

be reproduced for training purposes if distributed free of charge or
at cost and credit is given to ECHO. For all other uses, contact
echo@echonet.org for written permission.
PVC Water Pumps 2





TableofContents
_____________________________________________________________________________

PumpDesigns PumpPerformance
2 RowerPump 17 Definitionofterms
6 HandPressurePump 17 SomePrinciplesofwaterpumping
6 HandSuctionPump 18 RowerPumpPerformance
7 MarblePump 20 PerformanceofMarbleandInertiapumps
8 SockPump 20 Factorsthataffectpumpperformance
8 InertiaPump 21 DesigningaPump:Tradeoffs
8 ReciprocatingRopePump 22 Alternativedesignsforcomponents
9 TreadleSuctionPump 23 Testingmethodologyanddata

ManufacturingProcesses Appendix
10 SoftenPVCbyheating 25 Imperialtometricconversions
11 FlarePVCpipe 25 Acknowledgments
11 MakePVCsheet 25 Bibliography
12 CompressPVCpipe 25 Contactformoreinformation
12 CutPVCdiscs
13 DrillPVCwithahanddrill
13 Tapthreadedholes
14 Markaradialvalveholepattern
14 Findtheexactcenterofacircle
15 Deburraholeorpipe
15 Punchaholeinrubbersheet
15 Cutadiscfromrubbersheet
16 CutPVCpipesquare
16 GluePVCpipe
16 GlueaPVCdisctotheendofapipe
16 GlueaPVCdiscinsidetheendofapipe
16 Makealargehoseclamp
16 HeatformaholeinPVC
16 BendPVCpipe






PVC Water Pumps
PumpDesigns
RowerPump
Therowerpumpisoperatedusingthearmandback
musclessimilartorowingaboat.Thecylinderis
mountedhorizontallyandthehandleisattacheddirectly
tothepistonrod.Itcanbepositionedeitherforstanding
orseatedoperation.Theergonomicposition,combined
withthe3footstroke,givestherowerpumpan
outputof1020gallonsperminute,muchhigherthan
otherhandpumps.Liftisupto27feetsuctionandat
least8feetpressurewiththeuseofarodseal.
Rowerpumpinstalledataborehole
Components
Dimensionsofallcomponentswilldependonsizesof
availablePVCpipe.Listedvaluesareforprototypes
builtatECHO.Criticalrelationshipsbetween
dimensionsarediscussed,allowingthedesignertobuild
apumpsuccessfullyfromanysizepipehedesires.
Rowerpumpcomponents
PumpCylinder
Material:2Sch.40PVCpipe
Length:43
3
Thepumpcylinderisthebodyofthepumpinwhichthe
pistonslidesupanddown.Deburrbothendsofthe
pipeandglueaTeeontothetopend.Notethat
AmericanPVCismeasuredbytheinnerdiameter,while
WestAfricanPVCwhichismeasuredbyouterdiameter.
Sch.40ismediumwallpipe.
InletPipe
Theinletpipeextendsfromthefootofthecylinderinto
thewater.Thetopoftheinletmustbeequaltothe
pumpcylinderdiameter,butitcanbereducedtoa
smallerdiameterpipetosavecostandreducepriming
time.Asaruleofthumb,theinletpipediametershould
giveaflowareathatofthepumpcylinder.This
requiresaninletpipediameter0.707ofthecylinder.
Dontuseaninletpipelessthanthecylinderdiameter;
wastedenergyduetopipefrictionwillbecome
significant.However,ifyoubuildasurgechamber,
smallerinletpipecanbeused(seethetestingsection).
Theinletpipewillneedtobebentdependingonthe
watersourceandthemountingangleofthepump.See
themanufacturingsectiononbendingpipe.Ifasharp
bendisneeded,usea45or90degreefitting.
FootValve
Thefootvalveisacheckvalve(onewayvalve)that
allowswaterintothebottom(foot)ofthecylinderbut
notbackout.Arubberwasherisboltedtothecenterof
aPVCdiscwitharadialarrayofholes.ThePVCdiscis
gluedtothetopoftheinletpipeandthecylinderis
heatedandflaredovertheinletpipe.Therubberflaps
upwhenthepistonsuckswaterintothecylinder,but
bridgesovertheholeswhenthewaterreverses
direction.
Tightentheboltuntiltherubberjuststartstoliftatthe
edges.Iftherubberiscompressedtoomuchinthe
center,theedgeswillliftupinaconeshape.Thiswill
notpreventthevalvefromclosingduringoperation,but
canmakeitbounceopenandloseprime.
Explodedviewoffootvalvecomponents
PVC Water Pumps 4

Footvalvediscdimensions
Assembledfootvalve

HoseClamp
RubberValveFlap
Thefootvalveisheldinplacewithahoseclamponthe
Material:Truckinnertuberubber(orotherrubbersheet
footofthecylinder.Makeeightcuts1/2deepintothe
1/16thick)
endofthecylindersotheplasticcanflexintogripthe
Useacircularpunchtomakethecenterhole;thiswill
inletpipe.Beforeputtingonthehoseclamp,wrapthe
keeptheflapcenteredandreducethechanceofit
jointtightlywithastripofbicycleinnertube.This
pullingoffthebolt.Therubbershouldoverlapthevalve
providesadditionalsealagainstthesmallamountofair
holesbyatleast1/16topreventitfrombeingsucked
thatwillbeabletoleakbetweentheinletpipeand
intotheholeattheedge,breakingtheseal.Itshouldbe
cylinderfoot.
atleast1/16fromtheedgeofthePVCvalvediscto

preventitfromcatchingoninsideofthepumpcylinder
whereitflaresoutoverthefootvalve.Bicycletube
rubberisnotstiffenoughtobridgethevalveholes,
althoughlayeringseveralpiecesmaywork.

Rubbervalveflapdimensions
PVCValveDisc
Material:4Sch.40PVCpipe,flattened(aboutthick)
Togettheedgeexactlyflushwiththeinletpipe,cutthe
discslightlylarger,glueittotheinletpipe,andfileit
downtothepipe.Whentappingthecenterhole,only
runthetappartwaythroughsothattheboltstartseasily
buttightensup.Makesurethevalveholesareatfar
enoughfromtheedgesothattheinletpipeunderneath
doesnotblockthem.Seethesectiononalternative
checkvalvedesignsfortipsongettingthemostflow
areaforyourpipesizewithoutweakeningthevalve.
Thefootvalvejoint,wrappedinrubberandhoseclamped
SurgeChamber
Material:4PVCpipeandreducers
Length:18
Thesurgechamber(optional)isbelowthefootvalve.It
absorbssharpvacuumspikescreatedbythepistonand
evensouttheflowofwateruptheinletpipe(seethe
sectiononpumpperformance).Thesurgechamber
shouldhaveavolume2xthepumpcylinder.The
diameterandlengtharenotimportantifthisvolumeis
maintained.

PVC Water Pumps
Surgechamberonrowerpump
HeadSeal
Theheadseal(rodseal)sealsaroundthepistonrodso
thatwatercanbepumpedtohigherelevation.Arubber
washerissandwichedbetweentwoPVCdiscs,witha
PVCbushingontoptokeeptherodcentered.These
componentsmustbeassembledonthepistonrodbefore
attachingthehandle.Theyshouldfitsnuglybutnot
tightlyintotheTeesotheyareeasytoremovefor
maintenance.
Explodedviewofheadsealcomponents
Rubberwasher
Material:truckinnertubeatleast1/16thick
Thecenteriscutusingacircularpunch.Itisvery
importantthatthecutissmooth,assmallcutsandtears
willpropagateunderthecyclicloading.Thediameter
shouldbe1/16smallerthantheroddiametertogivea
goodsealwithoutexcessivefrictionandstressonthe
rubber.Doubleuprubberwashersiftheyarenotthick
enough.
Rubbersupportdiscs[2]
Material:4PVCpipe,flattened(about1/4thick)
Thediscthicknessisrequiredsothatastherubberflexes
upanddownwiththerod,itisnotcaughtintherod
bushingaboveit.Theholediametershouldbeatleast
fourrubberthicknesslargerthantheroddiameterto
5
preventtherubberfrombindinginthegapasitflexes
upanddown.
Rodbushing
Material:PVCorHDPEplastic
Thepurposeofthebushingistokeeptherodcentered
soitdoesnotdeformtherubberandallowleaks.HDPE
(#2)plasticwearsmuchbetterthanPVCandhashigh
lubricity.Someplasticbarrelsaremadefromit.Itcan
beflattenedbyheatthesameasPVC.Woodisanother
option:Awoodbushingcanreplaceboththebushing
discandtheretainerring.Therodshouldslidethrough
thebushingwithaslittleclearanceaspossiblewithout
sticking.Ifyoulackprecisecuttingtools,seeHeat
formaholeinthemanufacturingsection.
RetainerRing
Thisisasmallsectionof2pipeinsertedabovethehead
sealcomponentstoholdtheminplaceandgivethehose
clampsomethingtogrip.Sizeittoleaveasmallamount
protrudingfromTeefittingtoallowatooltogripit
shoulditbecomestuck.
HoseClamp
Makeeightcuts1/2deepintothetopoftheTeesothe
plasticcanflexintogriptheretainerring.
Piston
Thepistonslidesupanddowninthecylindercreating
suctiontopullwaterintothepump.Inthispiston
design,therubberdiscsservebothasthepistonsealand
asthecheckvalveflap.Onthedownstroketherubber
foldsoutofthewayasthepistonmovesthroughthe
watercolumn.Ontheupstroke,therubberissucked
downagainstthePVCdiscandwaterpressureforcesit
outagainstthecylinderwall,sealing.Thisdesign
pumpssandverywellbecauseoneverystroketheseal
breakscontactwiththecylinder,allowingany
accumulatedsandparticlestobeflushedout.
Explodedviewofpistoncomponents
PistonValveDisc
Material:4PVCpipe,flattened(aboutthick)
PVC Water Pumps
Thediameterofthediscshouldbe1/8lessthanthe
cylinderdiameter,giving1/16clearancewiththe
cylinderonallsides.Itisimportantthatthediscbe
exactlycircularandthattheholebeexactlyinthecenter.
Waterleakageandfrictionwillincreaseastheprecision
ofthevalvediscdecreases.Whentappingthecenter
hole,onlyrunthetappartwaythroughsothatthebolt
startseasilybuttightensup.
Pistonvalvediscdimensions
RubberValveFlap[23]
Material:Truckinnertuberubber(orotherrubbersheet
1/16thick)
Thediametershouldbe1/16greaterthanthecylinder
diameter.Thisallowstherubbertofollowirregularities
inthecylinderwallwithoutbreakingcontactor
bunchingupattheedges.Itisimportantthattheflapbe
exactlycircularandthattheholebeexactlyinthecenter.
Waterleakageandfrictionwillincreaseastheprecision
ofthevalveflapdecreases.Useacircularpunchto
makethecenterhole;thiswillkeeptheflapcentered
andreducethechanceofitpullingoffthebolt.Dont
usebicycletuberubber;itwillstretchatthecenterhole
andtheflapswillbepulledoffcenterandbindbetween
thePVCdiscandcylinderwall.
Thenumberofrubberdiscswilldependonthethickness
oftherubberandthegapsizebetweenthevalvedisc
andcylinderwall.Asaruleofthumb,thetotalrubber
thicknessshouldbeequaltothegapdistance.Ifthe
rubberistoothin,waterwillleakpast;iftoothick,
frictionwillbeexcessiveandthepistonmaybindinthe
cylinder.Tip:addmorerubberdiscsuntilyoufeelthe
rubbergrabbingthecylinderwallwhenyoupullslowly
onthepiston,thenuseoneless.
PistonBolt
Thepistonboltis5/1618x1long.Usegalvanized,
stainless,orpaintedhardwaretoresistcorrosion.
Woodplug
Material:hardwood
6
ThewoodplugisinsertedintotheendofthePVCpiston
rodbyheatingit.Theplugistaperedwiththelargeend
insertedfirsttolockitinplace.Thesmallendisslightly
largerthanthepipediameter.Iftheendoftherodis
greaterthandiameter,bevelitsothepistonvalve
holesarenotblocked.Inthecenteroftheplug,a1/4
holeisdrilledthroughandtapped5/1618toreceivethe
pistonbolt.Tapasdeepasthetapwillgo.
PistonRodandTHandle
Material:PVCpipeandTee
Length:Rodis44,eachsideofhandleis5
Gluebothsidesofthehandle,butattachtherodwith
twoscrewsthroughthesideoftheTee.Therodmustbe
detachedtoreplacetheheadsealrubber.PVCpipeis
chosenbecauseitissmoothandwillwearslowlyonthe
headseal.Anaddedbenefitisthatthehighflexibilityof
thinpipeallowssidetosidemovementofthehandle
withoutputtingstressontheheadseal.Ifthepumpis
abused,thehandlewillbreakfirst,ratherthanbreaking
theheadsealorcylinder.Thepistonrodismosteasily
replaced.Seetheappendixforadditionalhandleand
pistonrodoptions.
Installation
Cylinderangle
Thebestangleforthecylinderwilldependonwhether
youhavearodseal.Ifyes,setthepumpcloseto
horizontal,withthefootvalvethreeinchesbelowthe
headseal(thiswillkeepwateronthefootvalvesoit
doesnotloseprime).Ahorizontalpullismost
ergonomicbothfromastandingandseatedposition.If
norodseal,mountthepumpatasteeperangle,30deg
fromhorizontal,toreducethedistancewatersplashes
outofthetopofthecylinder.
Securingthepump
Oneoptionistoburrythepumpinamoundofdirt.
Anotheristoplanttwosetsofpolesinthegroundatthe
headandfootofthecylinder.Insertapegthroughtwo
polessothepumpcanrestbetweenthemonit.Lashthe
polestogethertosecurethepump.
PVC Water Pumps 7
Thispumpworksmostefficientlyifsomewaterleaks
pastthepistonseal,providingawaterbarriersoair
cannotleakpastthesealontheupstroke.Toventthis
watersoitdoesnotblowoffthecap,aholeisdrilled
inthetopofthecylinderdirectlybelowthecap(onthe
darksideofthebelowphotograph).Thecylindercapis
onlytosupportthepistonrod.

Rowerpumpclampedbetweentwosetsofpoles

SunProtection

PVCdegradesinUVlightandbecomesbrittle.Paintthe
pump,coveritwithashelter,orburyitinamoundof
dirt.

OtherRowerDocumentation
TheMennoniteCentralCommittee(MCC)hasagood
constructionmanualfortheirversionoftherower
pump.Thisdocumentisavailableinelectronicformby
requestfromECHO.
HandPressurePump
Handpressurepump
Thepistonsealissimilartotherowerpump,buttwo
rubbersealsareused,oneoneithersideofthePVCdisc.
Thiscreatesasealwhenthepistonmovesineither
direction.ThepistonrodisPVCpipewithanendcap,
tappedtoaccepttheboltthatholdstherubberandPVC
discinplace.

Thehandpressurepumpisoperatedsimilartoabicycle
airpump.Itisintendedtobeplacednearawatersource
andforcewateruphilloroveragreatdistance.The
pistonissolid,pullingwaterintothecylinderthrough
onecheckvalveandexpellingitthroughanother.Check
valvesareradialflappervalvesinsertedinbothendsof
theTeeatthebottomofthecylinder.Theendsofthe
Teeareslottedsimilartotheheadandfootoftherower
pump;byremovingthehoseclampsthevalvediscsmay
beremoved.Thecylinderis2diameter.The1plastic Handpressurepumppiston
hoseandballvalvepicturedbelowarefortestingonly;
liketherowerpump,itisrecommendedtousesuction
anddischargepipingatleasttheareaofthecylinder.

PVC Water Pumps 8
HandSuctionPump

Thehandsuctionpumpissimilarinconstructiontothe
rowerpump.Itismoreportableanddoesnotneedto
beanchoreddown.Outputisprobablysimilarbuthas
notbeenmeasured.Thepumppicturedbelowhasa3
cylinderand2suctionhoseforlargevolumeatlowlift.
Itismostcomfortabletooperatethispumpifthelength
ofthecylinderrequiresyoutobendslightlyattheknees
whenpumping.Thiswillallowyoutopumpwithyour
legs.

Marblepump

Thefootvalveismadebycompressingthe1.25pump
cylinderoverapipe,thengluingthesmallerpipein
placetomakeaseatfora1glassmarble.Themarbleis
heldinplacebyapinthroughthecylinder,permitting
themarbletoriseofftheseat.

Handsuctionpump
MarblePump
Themarblepumpisnamedfortheglassmarblesused
forballcheckvalvesinthepistonandfootvalve.Water
isdeliveredthroughthepistonrodonthedownstroke.
Aflexiblehoseisattachedtotheendoftherodfor
delivery.Thispumpdoesnotneedarodsealtopump
uphill.Thesmalldiametermakesitappropriatefor
wellsbelowthesuctionlimit.Itworksbestasalift
pump(thefootvalveandpistonshouldbesubmerged
inthewater).
Marblepumpfootvalve
TheplungerisPVCpipe.Ashortsectionofpipe
isinsertedintotheendbyheating.AringofPVC
pipeisinsertedovertheendofthepipe,creatinga
grooveinwhicharubberoringsits.Theoringshould
beloose,buthavenotravelupanddowninitsgroove.
Themarbleseatsontopofthepipeandisheldin
placebyapinthroughtherodthatpermitsittoraise
ofitsdiameterofftheseat.Inlieuofapin,therodmay
beheatedandcrimpedintoanovalshapetokeepthe
marbleinplace.

Marblepumppiston
PVC Water Pumps
SockPump
Thesockpumpisnamedforthesockvalveonthe
plunger.Abicycleinnertubeistiedtotheendofthe
plungeroverarowofholes.Theplungerpipeis
pluggedabovethevalveholes,andendoftheplungeris
flaredouttoslidelooselyinthepumpcylinder(a
woodenmoldwasturnedonalathetomakethisflare).
Thispumpusesthesamefootvalveasthemarblepump
(anytypeoffootvalvecanbeused).Onthedown
stroke,waterisforcedupthroughtheplungerandout
throughtheholes,butistrappedontheupstrokebythe
sockvalve.Theflaredplungerformsanimperfectseal,
butathighspeedtheleakageisnegligibleandis
compensatedforbylackofthemechanicalfrictionofa
rubberorleatherseal.Waterdeliveryisthroughthe
risingmain,nottheplunger.
Sockpumpplunger
InertiaPump
Theinertiapumphasnopistonvalve.Thepistonisa
PVCpipewithaplugintheend.Thecylinder/rising
mainis1.25pipe.Anytypeoffootvalvecanbeused,
butitmustbesubmergedatleast4feetbelowthewater.
9
ofitwillbepulledbackdownintothecylinder,butif
thespeedoftheplungerishigh,thiswillbelowenough
thatasignificantamountofwatermaybeliftedupthe
risingmain.
Thepumpingheadshouldnotchangetheamountof
waterthatfallsbackintothecylinderontheupstroke.
Objectsthrownupwardundertheinfluenceofgravity
willfallatthesamerateindependentoftheirmass.
Pumpingheadwillaffecttheforcerequiredtopushthe
plungerdown.
Thesmallerthegapbetweenplungerandcylinder,the
morequicklythispumpwillprime.However,atsome
point,frictionwillbecomesignificant.
ReciprocatingRopePump
Thereciprocatingropepumpisadeepwellpumpin
whichthepistonisattachedtoamassandraisedand
loweredonarope(ithasnopistonrod).Themass
providestheforcenecessaryforthedownstroke.Atthe
topofthepumpisapulleyorrollersothattheropecan
bepulledhorizontallyinarowingmotion.Thepiston
andfootvalvecomponentsareotherwisethesameas
therowerpump.Mymeasurementsoftherowerpump
haveshownaforceofaround14lbsisnecessaryforthe
pistondownstroke.Because14lbisalottoaddtothe
handleforceofapump,theweightonthepistoncanbe
reduced,withtheresultthatitreturnsmoreslowly.In
thephotographbelow,thepistonweighs10lbandthis
givesatolerablereturn.

Thispumpismostappropriatefordeepwellswhere
eliminatingthepistonrodcangreatlyreducethecost
andmakeextractingthepistonmucheasier.

Inertiapumpplunger

Theplungerisworkedrapidlyupanddown.Onthe
downstrokeandplungerdisplacesmostofthewaterin
thecylinder;thewatershootsrapidlyupinthesmall
gapbetweentheplungerandcylinder.Whenthe
plungerreversesdirection,theinertiaofthewaterkeeps
itmovingupwardforamoment,creatingapressure
dropinthecylinderthatpullsmorewaterthroughthe
footvalve.Thewaterwillloseitsmomentumandsome
PVC Water Pumps 10

Reciprocatingropepump


TreadleSuctionPump

Thisisanopentoptreadlepumpmostsuitedforfilling
irrigationcanals.Ithasnospouttodirecttheflowof
Treadlesuctionpump
water.Ithasnobasetositon,butratherapostthatis

setintotheground.Withwaterpouringaroundit,the
ThecylindersarePVCpipe.Thekeytosuccessfully
soilquicklysettlesfirmlyaroundthepost.Ifthepump
usingthisweakmaterialinatreadlepumpistoisolateit
canbesetdowninaditchsothatthebaseofthe
fromanystructuralloads.Waterandpistonsealfriction
cylindersissubmergedinwater,itwilleliminateany
shouldbetheonlyforcesonthepipe.Inthemodel,the
suctionairleaks.
cylindersareclampedtotheverticalframemember.

Thetreadlespivotona5/8steelrodwhichkeepsside
tosidewobblelow.Cotterpinsratherthannutsare
usedonthepivotrods.Theydontfreezeonandare
easytomakefromsteelwire.

Thebaseofthecylinderisa2Teeandelbowfitting
withringsof3pipecompressedoverthemtoexpand
thediameter.2pipeisgluedintothefittingsand
sawedoffflushtogiveawidesurfaceforthevalveseat.
Rubberflappervalvesarescrewedontotheseat(cutthe
rubberfromatiresidewall).The3cylindersarethen
flaredoverthefootvalves.

PVC Water Pumps 11
maximumtravelofthepistons;astheropestretches,the
pistonswillsitlowerinthecylindersandthestroke
lengthwillreduce.

Ropeattachmentdetail


ManufacturingProcesses


SoftenPVCbyHeating

PVCbecomessoftandpliablewhenheatedbetween225
PVCcylinderdetail and275degF.Thisbehaviorcanbeexploitedtomake
flaredpipeconnectionsandflatPVCsheet,increasing
Pistonsaresimilartotherowerpump,butsizedfor3 theversatilityofthismaterialinareaswherepipe
pipe. couplingsandflatsheetaredifficultorexpensiveto
obtain.Hotairandhotoilmaybothbeusedtoheat
PVC.Oilismoredesirablebecauseitgivessteady
uniformheat,butittakeslongertoreachworking
temperatureandisdangerousifspilledoraccidentally
heatedtoflashpoint.Caution:ifheatedbeyond275
degF,PVCwillscorchandthefumesgivenoffcontain
dioxins,neurotoxinsthatbioaccumulateinbodytissue.

Hotoilbath

Heattheoilslowly.Testthetemperaturewithapieceof
PVCwhileheating.Itshouldnotshowanysignsof
scorchingwhenheldintheoilforanylengthoftime.
Oilhasmuchbetterheattransferpropertiesthanairso
thedesiredoiltemperaturewillbeonlyslightlyhigher
thanthedesiredPVCtemperature.

HotAir

Pistondetail
Aircanbeheatedbypropanetorch,electricheatgun,

fire,etc.Directingthisheatagainstthepipeisbest
Theropeisanchoredtothetreadlesbyhookingitover
accomplishedbyputtingaskirtaroundthepipe.Itis
protrudingpinsontheoutsideofthetreadleboard.
importanttokeepeitherthepipeortheheatsource
Thismakesiteasytoadjusttheropelengthtoallowthe
PVC Water Pumps
movingconstantly,astheairtemperaturewillbevery
nonuniform.Airtemperaturewillalsobemuchhigher
thanthedesiredPVCtemperature.Airhaslowheat
transferpropertiesandunlessalargetemperature
differenceismaintained,thePVCwillheatveryslowly.
Herearesomeexamples:
1. Apropanetorchwithskirtmadefromatincan.The
torchheatstheairinthecanatthebottomandthe
pipeisinsertedthroughaholenearthetop.The
pipeshouldberotatedconstantlyforevenheating.
2. Anelectricheatgunwithatincan.Thepipeis
insertedintotheopentopofatincanandanelectric
heatgunisaimeddownintothecan.Keeptheheat
gunmovingtogiveevenheating.
3. Holdthepipeoverafire.Enoughheatisrisingover
alargeareasoaskirtisnotneededtocontainheat
aroundthepipe.Ittakespracticetoheatwithout
scorching.
HeatingPVCwithatorch
HeatingPVCwithanelectricheatgun
FlarePVCpipe
Thisprocessstretchesthepipe,increasingitsdiameter
soitwillfitoveranotherpipe.Heattheendofonepipe
untiluniformlysoft,theninsertitovertheotherpipe.
Allowtocoolenoughtoholdinthehand,thenpullthe
twopipesapartwhilebendingthejointbackandforth
toloosenit.Onlyflareapipeusingthepipethatitwill
bejoinedto:Theheatfromtheflaredpipecansoftenthe
12
otherpipeandcontractitslightly.Toreducethiseffect,
coolthepipeeveryfewsecondsbypullingitoutofthe
flaredpipeanddunkinginwaterbriefly.Ifyouneedto
makealotofflaredends,itmaybeworthwhiletoturna
woodenmoldonalathe.Themoldcanbemadeafew
thousandthsofaninchlargerthanthepipediameterto
alloweasierinsertionofthepipe.
AflaredPVCjoint
MakePVCsheet
Cutashortsectionofpipelengthwisesoitcanbe
unfolded.Heatthepipeuntiluniformlysoftandspread
flatandpressbetweentwosmoothandrigidsurfaces.
Allowtocooluntilwellsolidified.Usealotofweight
whenpressingthesheetflat,otherwiseitwillhave
ridgesandripples.SoftPVCdoesnotflowlikepie
dough;itremainstoughandrubbery.PVCismadeof
chainsofpolymersthatcanslidepasteachotherwhile
abovetheglasstransitiontemperaturebutalways
remainpartiallyconnectedbycrosslinkmolecules.
Whenpressedbetweentwoperfectlyflatsurfaces,the
PVCsheetwillstillhaveaslightconvexshapewhen
removedduetoresidualstressesinvolvedinunbending
thepipe.Tomakeitperfectlyflat,trypressingbetween
twoslightlyconcavesurfaces,suchaswidewoodplanks
thathavewarpedorcupped.Havingbeenoverbent,
thesheetwillspringbackintoamoreflatstate.PVChas
amemoryandifyoureheatyourflatsheetagain,itwill
curlbackintoapipe.
FlatPVCsheet
PVC Water Pumps
CompressPVCpipe
TheprincipleofflaringPVCpipecanalsobeappliedto
reducethepipediameter.Putahoseclamparoundthe
endofthepipe,heatthepipeuntiluniformlysoft
underneaththehoseclamp,insertthesmallerpipeand
tightenthehoseclampuntilthelargerpipehas
compressedagainstthesmaller.Smallerpipeswillbe
lopsidedwhencompressedbecausethehoseclamp
screwmechanismputsaflatdentinonesidethat
becomesincreasinglynoticeableinsmallerdiameters.
1.25pipecompressedonto3/4pipewithhoseclamp
CutPVCdiscs
Withalathe
DrillaholeinthecenterofapieceofPVCsheetandbolt
toasteelrodtoclamprodinlathechuck.
Note:5/8diametersteelrodistapped5/1618to
receiveaboltwhichclampsthediscagainsttheendof
therod.Thisprovidesagoodfrictiongriponthedisc
andresistsbendingforcesappliedbythecuttingtool.
Alternatively,astandardboltorthreadedrodwithtwo
nutsmaybeusedtoholdthePVC.
PVCdiscturnedonlathe
Withaholesaw
1. Selectholesawsize
13
a) Ifanadjustableholesaw,loosenthenutand
rotatethetwohalvestoslidethecuttingteethin
andouttogivethecorrectdiameter(notethat
youneedaninnerdiameterbecauseyouwantto
keepthecenterofthecutout).Tightenthenut.
b) Ifafixeddiameterholesaw,findonethatis+/
1/8ofthedesireddiameter(rememberto
measuretheinsidediameterofthesaw).
2. ClampthePVCsheettoscrapwoodtosupportthe
sawasitcutsthroughthebacksideofthesheet.
3. Useeitherahanddrillordrillpresstocutthehole
a) Handdrill:Clampthescrapwoodtoasecure
object(workbench,vise).Holdthedrillwith
bothhandsandtakecaretokeepitsteadyand
straight,asthiswillreducethechangeofthe
sawcatchingandwrenchingthedrilloutof
yourhands.Runatamediumspeedandfeed
thesawslowlyintothework.Withdrawthe
sawfromtheworkoftenandcleantheteeth
withawirebrush,astheplasticmeltstothem
andclogsthesaw
b) Drillpress:Clampthescrapwoodinthedrill
pressviseandadjustthetableheighttobring
theworkclosetothesaw.Turnonthedrill
pressandadjustthespeedto600rpm.Feedthe
sawslowlyintothework
4.Removetheholecenterfromtheholesaw.
Fixedholesaw(left)andadjustableholesaw(right)
HoleSawingusingahanddrill
PVC Water Pumps
HoleSawingusingadrillpress
Withasawandfile
1. MarkoutthediscdiameteronthePVCsheetwitha
compassorbytracinganobjectofthecorrectsize.
2. Cutoutsideofthislinewithmultiplesawcutsto
givetheapproximateshapebutleaveextramaterial
forthefiletoremove.
3. Filetheremainingpointsdowntotheline.Make
suretoholdthefileperpendiculartothediscsothe
edgeisnottapered.
Straightcutsaroundperimeterofdisc,edgefiledround
DrillPVCwithahanddrill
PVCissoft,andalargebitwillwanderaroundalot
beforeitgetsindeepenoughtokeepitselfcentered.
Tomakeastraightroundholeinthecorrect
location,drillasmallpilothole(1/8)first.Thiswill
doalottokeepthebitcentered.Forevenmore
accurateholes,stepupthediameterbyincrements
of1/8untilyoureachthedesireddiameter.Note:
14
Drillpressesholdboththeworkandthebitrigidly
andthereislittlebenefitfrompilotholes.
Twistdrillbitswillpullthemselvesrapidlythrough
asoftplasticlikePVC,particularlywhentheyhavea
pilotholetofollow.Thisrapidcuttingofalarge
chunkoutoftheplasticcancauseittocrack,
especiallyiftheholeisnearanedge.Trytodevelop
theskillofpushingthedrilltogetittobite,then
pullingbackonittodrilltheholeinaslow
controlledmanner.
Drillrpmdependsonthesizebit.Smallbitsmust
beturnedveryfasttoexpelthechipsfromtheflutes
onthebit.Largebitsshouldbeturnedslowly.The
speedofthecuttingsurfacesincreasesasthe
diameterincreasesandtherpmmustbedecreased
inthesameproportiontopreventexcessiveheat
buildupthatwilldamagethebit.Thisisvery
importantwhendrillingmetal,butwithsofter
plasticitisnotanissueandbitscanberunfaster.
Tapthreadedholes
Atapisusedtocutinternalthreadsinthehole.Tapping
apartofteneliminatestheneedforanutonthebolt.
1. Drillaholesmallerthanthethreadsize,
approximatelyequaltothediameteratthebaseof
thethreads.Tapdrillchartswillgivetheexactsize.
2. Twistthetapdownintothehole;pushtogetit
startedbutafterthatitwillpullitselfin.
TappingthreadsinaPVCdisc.
Iftappingmetal
Lubricatethetapheavilywithcuttingoil.Turnthetap1
turnforward,1/4turnbackwardtobreakthechipthatis
formedasmetalisshavedofftheinsideofthehole.This
willpreventthetapcuttingteethfromgettingclogged
PVC Water Pumps 15
andbinding.Veryeasytotwistatapinhalfifyoudont
followthisprocedureinmetal.Notanissuewithsofter
plasticandwood.

Ifthereisnotap...

Whenthreadingaboltintoplasticorwood,itisnot
necessarytotapthehole,themetalboltwillcutitsown
threads,althoughitwillgoinwithmuchmore
resistance.Ifyouhaveaveryhardwoodorplastic,
tappingisprobablynecessarytokeepfromsplittingthe
wood.Ifthereistoomuchresistance,theholecanbe Markingholecenterswithacompass
drilledoutlarger,butkeepinmindthatlessthreadwill
beincontactwiththewoodandthereforelessholding Freehand
power.
Drawdiameterlinesdividingthediscintosixroughly
Acrudetapcanbemadefromasteelbolt.Cutaslitin equalsegments.Measurefromthecenteroredgeofthe
theendofthebolt;thecutedgesofthreadwillbesharp discandmarktheholecenters.
cuttingsurfaces.Aluminumcanbetappedwiththis
method. Makeatemplate

Cutadiscfromsheetmetalandmarkoutthehole
pattern.Punchasmallholetomarkthecenterofeach
hole.ThemarksareeasilytransferredtothePVCdisc
withacenterpunch.

Asteelboltslitattheend,usedtotapsoftermaterials

Markaradialvalveholepattern

Withacompass

Scribeacirclethatwillpassthroughthecentersofthe
holes.Keepingthecompassatthesameradius,place
thepointontheedgeofthecircleandsteparoundthe
circlemakingmarksateachstep.Thiswilldividethe
circleintosixequalsegmentsandmarkthecentersof
theholes.
Holepatterntemplate
Findtheexactcenterofacircle
Placethepointofasquareontheedgeofthecircleand
markwheretheedgesintersectthecircle.Drawaline
connectingthesetwomarks;itwillbeanexactdiameter.
Drawtwoorthreediametersandmarkwherethey
intersect.
PVC Water Pumps
Indexcardusedtomarkendpointsofacirclediameter.
Deburraholeorpipe
Withadeburringtool
Dragthecuttingedgeclockwisearoundtheinsideedge
ofthehole,applyingfirmpressure.Deburringtoolscut
inonlyonedirection,mostlikelyclockwise.
Deburringtoolremovingburrsoninsideedgeofpipe
Withafile
Toavoidmakinggroovesincurvedsurfaces,movethe
filesidewaysaroundtheinsideofthepipe(drawfile).
Filescutonlyinonedirection,usuallyawayfromyou.
Dontcutbackwards,itdullstheteethandplugsthem
withfilings.
Filingtheinsideedgeofapipe
16
Punchaholeinrubbersheet
Circularpunchesmakeacleancutinasoftmaterialsuch
asrubber.PlaceapieceofflatPVCorhardwood
underneaththerubbertocutagainst(dontusemetal,it
willdullthecuttingedge).
Fromlefttoright:standardcircularpunch,metalpipe
sharpenedtoacuttingedge,valvestemsharpenedtoacutting
edge,drilledoutmetalstocksharpenedtoacuttingedge.
Cutadiscfromrubbersheet
Option1:PVCtemplate
1. Tracethetemplate(centerholeandouterdiameter)
ontorubbersheetandcutoutsideoflinetoleave
1/8extramaterial
2. punchthecenterhole
3. bolttherubbertothetemplateandcutaroundit
withscissors.Makestraightcuts,keepingthe
scissorsbladevertical.Donottrytofollowthe
curveofthetemplate,asthiswillstretchtherubber
andthecutwillnotfollowthetemplate.
Rubberdiscbeingcutontemplate
PVC Water Pumps 17

Option2:freehand GlueaPVCdiscinsidetheendofapipe

1. Tracearoundanobjectofcorrectsize.Or,tracean
Cutthedisctofitexactlyintothepipewithnolarge
objectclosetothecorrectsizeandmeasurefromthis
gaps
lineandmakeseveralmarksaroundthe
Ifyouarenotsuccessfulatgettingagoodfit,heat
circumferencetoguideyou.
thepipeandcompressitaroundthedisc.Mark
2. Cutoutthediscwithscissors.
theirpositionrelativetoeachother.
3. Findthecenterandpunchthehole.
Useplentyofgluesothatgapsarefilled.

CutPVCpipesquare Makealargehoseclamp

Constructamiterboxfromwood.Thisisachannelthat
willcradlethepipesecurelywhileyoucut.Ithasaslot
(cutwithyoursaw)perpendicularacrossittoguidethe
sawblade.Onevariationonthestandardmiterboxisto
hingeoneflangeofthechannel,makingthebox
adjustableforseveralsizesofpipe.

GluePVCpipe
1. Deburrtheedgesofthepipeandfittingsotheydo
notscrapeoffthegluewhenthepipeisinserted.
2. ApplyPVCprimertobothsurfacestocleanand
softenthepipesurface.Allowprimertodry,
leavingatackysurface.Donotgetprimeronparts
ofthepipethatwillnotbegluedtogether,ithas
beenfoundtoweakenthepipeleadingtofailure.
3. ApplyPVCcementtobothsurfaces.Insertthepipe
intothefittingwhilerotating1/4turntoevenly
distributetheglue.Holdfor30secondsuntilsetup.
Thejointwillcureoverafewhourstoreach
maximumstrength.
GlueaPVCdisctotheendofapipe
Makesuretheendofthepipeissquareandflatand
thediscisflat.Toresolveslightproblemswith
eithersurface,heatthediscandpressthepipedown
ontoituntilitsolidifiesagain.Marktheirposition
relativetoeachother.
Whengluing,applyfirmpressuretoholdthedisc
againstthepipeandholditforafewminutesat
least.Unlikeapipejoint,thereisnoforcetokeep
thepiecesfromspringingapartwhilethegluesets.
Letcureforseveralhoursbeforedoinganything
withthisassembly.
Twohoseclampslinkedendtoend
HeatformaholeinPVC
Ifyouneedaholeofexactsizeforarodbushing,butdo
nothavethenecessarytools,trythis:
1. Drillaholethenextsizesmallerthanthedesired
hole
2. Heattheedgeoftheholetosoftenit.
3. Inserttherodtospreadtheplastic.IftherodisPVC
pipe,keepitmovinginandouttoavoidsoftening
therod.
ThisworkswithPVCandHDPE(#2plastic).Ifthehole
hastobespreadsignificantly,itwillprobablybe
difficulttogettherodstarted.Trybevelingtheendof
therodormakingataperedmoldfromwood.
BendPVCpipe
Fillthepipewithsandandcapbothends.Heatthe
sectiontobebentandformitaroundabucketorlarge
pipe.
PVC Water Pumps
PumpPerformance
Definitionofterms
PressurePump:apumpthatmoveswaterby
raisingitspressureaboveatmospheric
SuctionPump:apumpthatmoveswaterby
loweringitspressure.Atmosphericpressureforces
waterintothepump.
LiftPump:apressurepumpsubmergedinawell
Head:verticaldistancetowhichwaterisbeing
raised.
PressureLoss(HeadLoss):adropinpressurewhen
waterpassesthrougharestrictionorlengthofpipe.
Thisislostenergy.
RisingMain:Inaliftpump,thepipeconnectingthe
pumpcylinderwiththepumphead
SuctionPipe:Inasuctionpump,thepipefromthe
pumpcylinderdowntothewater.
PumpHead:Theabovegroundmechanismfor
operatingaliftpump
SweptVolume:thevolumesweptbythepistonin
thecylinderduringtheextentofitsmotion.This
maybegreaterthanvolumeofwateroutputif
pistonleakageissignificant;itmaybelessthan
volumeoutputifinertiaofwaterkeepsitmoving
significantlyafterthepistonreverses.
DirectActionPump:Thepumphandleisdirectly
attachedtothepistonrod(nopivotinghandleto
generatedleverage).
SomePrinciplesofWaterPumping
Pumpsmovewaterbycreatingapressuredifference
thatisgreatenoughtoovercomegravityandfluid
resistance.Inapistonpumpthisisdonebypositive
displacement:Thewaterisforcedtomovebyaclose
fittingpistoninacylinder.Theflowrateisconstant
withthedisplacementofthepistonandthepressure
varieswiththeresistanceofthepipeline.Ina
centrifugalpumpthewaterisspunwithanimpellerto
raiseitspressurebycentrifugalforceagainstthe
impellerhousing.Thepressureisconstantwiththe
rotationspeedoftheimpellerandtheflowratevaries
withtheresistanceofthepipeline.Thepowerrequired
tooperateapumpisproportionaltothepressure
18
differenceandflowrate.Ifnotenoughpoweris
available,apistonpumpwillstallandacentrifugal
pumpwillspinbutnotdeliveranywater.
Asuctionpumplowersthepressurebelow
atmosphericairpressuresothattheatmospherepushes
waterintothepump.Forthisreason,suctionpumpsare
limitedintheorytoamaximumdepthof34feet.In
practicethismaximumsuctiondepthisreducedto
around27feetduetolossesfromfluidfrictionandfrom
acceleratingthewateroneachpumpingstroke.A
pressurepumpraisesthepressureaboveatmospheric
sothatwaterispushedoutofthepump;theheightis
onlylimitedtotheenergysuppliedbytheoperator.
Somepumpsarecapableofbothsuctionandpressure
pumping.
Reciprocatingpistonpumpsrequiretwocheckvalves;as
thepistonmovesupanddowninthecylinder,wateris
suckedintothecylinderthroughonevalveandexpelled
throughtheother.
Sourcesofwastedenergyinpumpsare:
Fluidfrictionaswaterincreasesspeedtoflow
thoughsmallorificesincheckvalves.
Mechanicalfrictionofsealsagainstmovingcylinder
wallsandpistonrods.
Forceneededtoopen(crack)checkvalves.
Pipefrictioninthesuctionordeliverypipe.
Pipefrictionisoftenthemostsignificantbecausepipeof
toosmalldiameterisusedbecauseitischeaper.Flow
frictionincheckvalvesandslidingfrictioninsealscan
behighinapoorlydesignedpump.
Asuctionpumpcannotallowairtoleakpastitspiston
oritwillfunctionverypoorly.Itismoredifficultto
makeasealairtightthanwatertightbecauseairisless
viscous(itflowsmoreeasily).Ifthesealhassmallgaps,
negligibleamountsofwaterwillleakthrough,but
significantamountsofair.Thisissueiseasilysolvedby
havingwateronbothsidesofthepistonseal.Inmany
suctionpumpdesigns,oneofthecheckvalvesispartof
thepiston.Onthedownstroke,thepistonmoves
throughthecolumnofwaterinthecylinder.Onthe
upstroke,thepistonsimultaneouslyexpelswaterfrom
thecylindertopandpullsmorewaterintothebottom
throughthefootvalve.
Theneedtocreatesuctioncanbeeliminatedbyplacing
thepumpcylinderbelowwater.Mostwellpumpsare
PVC Water Pumps 19
ofthistypeandarereferredtoasliftpumps.Mostso 2. Flow Rate from a 2" Rower Pump as a function of Work
Input for Three Suction Pipe Options
calledpressuretreadlepumpshavepistonswhichonly
20
seewaterononeside.Thesearecapableofsuctionand 18
areadvertisedassuch,butwillworkmosteffectively 16
whenthepressureheadismuchgreaterthanthesuction 14

Flow Rate (gpm)

head.Watermustleakpastthesealsothateachpiston 12
haswatersittingontopofitanddoesnotsuckair. 10

8
6
Allofthepumpsdescribedinthisdocumentare
4
intendedtobeusedasdirectactionpumps,i.e.the
2
handleisdirectlyattachedtothepumprod.No
0
leverageisprovided.Thediameterofthepumpis 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20
determinedbasedonthewaterdepth.Thismakesthe Work Input (hp) 1" pipe with surge chamber
1" pipe
mostsensewhenyouarebuildingthepumpyourself 1.25" pipe
andhaveawiderangeofdesignoptions.Nothingis

gainedbyusingalargercylinderandthenshortening
Theseflowratesseemgooduntilyouconsiderthatyou
thestrokebyuseofalevertogainmechanical
areonlyliftingthewater7feet.Theforcerequiredto
advantage.Asmallercylinderwithalongerstrokecan
holdupacolumnofwatercanbecalculatedasF=
givethesamevolumeatlowercost.
ghA.

F=Force(lb)

=density1(slug/ft3=lbs2/ft4)
RowerPumpPerformance g=accelerationofgravity(ft/s2)
A=cylindercrosssectionalarea(ft2)
Thefollowingtests(graphs14)usedatwoinchrower
pumpinaborehole.Thesuctionpipewas27feetlong Forwater,g=62.4lb/ft3
andthewaterlevelwas7feetbelowthepump.
62.4lb 7 ft 3.14in 2 ft 2
2 2 9.5lb
ft 3
1. Flow Rate from a 2" Rower Pump as a function of Handle

20
Force for Three Suction Pipe Options
12 in
18 Itshouldonlytake9.5lbofforcetoliftthiswater.This
16 isknownasthestatichead,theweightofthewater
14
columnatrest.Therestofthehandleforce(dynamic
Flow Rate (gpm)

12
head)islostasfrictionmovingthewaterthroughthe
10
8
suctionpipeandfootvalveandasforceneededto
6 acceleratethewateroneachstroke.
4
2
0
20 25 30 35 40 45 50
Handle Force (lb)
1" pipe with surge chamber
1" pipe
1.25" pipe

1
Density is defined as mass per unit volume. A slug is a unit
of mass, analogous to the kilogram.
PVC Water Pumps 20
3. Force lost to Friction in 2" Rower Pump as a fuction of Flow fasttogivethesamevolume,thereforedynamiclosses
Rate for Three Suction Pipe Options
45
willbemuchlesssignificant.
40
Forlonghorizontalruns,pipefrictionlossesbecome
Handle Force Lost (lb)

35
30 moresignificantthanvalvelosses.Thefollowingtests
25
(graph5)useda2rowerpumpinaboreholewith
20
varyinglengthsofhorizontalpipe.Thesuctionpipe
15
10
diameterwas1.25.Theverticalsuctionpipewas9feet
5 longandthewaterlevelat7feetbelowthepump.
0
8 10 12 14 16 18 20
5. Flow Rate in a 2" Rower Pump as a function of Horizontal Run
Flow Rate (gpm) 1" pipe with surge chamber 20
1" pipe
18
1.25" pipe
16

14
4. Work Lost to Friction in 2" Rower Pump as a fuction of Flow

Flow Rate (gpm)

Rate for Three Suction Pipe Options 12
50 lb
0.18
10 40
0.16 30
8

0.14 6
Work Lost (hp)

4
0.12
2
0.10
0
0.08 0 20 40 60
Horizontal Run (ft)
0.06

0.04
8 10 12 14 16 18 20
Fromthischartweseethattheamountofwateraperson
Flow Rate (gpm) 1" pipe with surge chamber canpumpdecreasesabout3.5gallonsovera60footrun.
1" pipe
Asurgechamberandlargediameterpipearegood
1.25" pipe
investmentsforlongerruns.

Theseresultslookdepressing,butconsiderthatapump
Canwedecreasedynamiclossessignificantlybyusinga
thissizeisnotmeantforthehighflowratesseeninthis
lessrestrictivevalve?Thefollowingchartcompares
test.Thetwoinchpumpisbettermatchedtodeeper
pumpswithdifferentfootvalves.Oneisaradialpattern
wellswhereitwillhavemorestaticheadandtheuser
ofsix7/16holes,theotherisasideflappervalveovera
willnotbeabletopumpasfast,reducingthedynamic
single1.5diameterhole.Theflappervalveallowsa
head.
persontopumpfourmoregallonsperminutethandoes

theradialvalve.However,itmaystillbeinferiorforthe
Supposeawellis27feetdeep,apersoniscapableofa50
applicationbecauseitismoreeasilydamaged.
lbpull,andhispumphasasurgechamber:37lbof

handleforceisneededtoliftthewater(statichead),
Comparison of Radial and Flapper Check Valves
leavingonly13lbtowasteasfriction(dynamichead). 25

Fromchart3,hecanpumpabout12gpm.
20

Flow Rate (gpm)

Forshallowerwells,usealargerdiameterpump.The 15
Radial
Valve
rowerpumpcaneasilybemadefrom3or4pipewith Flapper
10 Valve
correspondingchangesinthevalvedimensions.A3
pumpcanprobablybeusedupto15feetdeep(static 5

headatthisliftrequires46lbhandleforce),anda4
0
pumpusedupto8feetdeep(43lbhandleforce).The 25 30 35 40 45 50 55
Handle Force (lb)
largerdiameterpumpswillnotneedtobestrokedas


PVC Water Pumps
Otherobservations:
IbuiltarowerpumpfromclearPVCpipeandobserved
thatifthepumpisstrokedfastenough,themomentum
ofthewaterwillkeepitmovingcontinuallyupward,
evenduringthedownstrokeofthepiston.Thefoot
valvewillneverclosecompletely.Thiseliminatesthe
problemofwaterleakingbackthroughthevalvewhileit
isclosing,andtheproblemofthevalveslammingshut
anddamagingtheseatortheflap.
Theorizingabouttheaboveresults,thesurgechamber
requireslessforceatthehandle,butvolumetric
efficiencyislowerbecauseasmallermassofwateris
accelerated.Morestrokesareneededtomovethesame
amountofwater,sothenetpowerrequiredissimilarto
thelargerpipe.The1.25piperequiredconsiderably
moreforceforagivenflowrate,butthisforcetakesthe
waterfurtherbecauseitsmomentumcontinuestomove
itupthepipeevenafterthepistonhasreversed
direction
Marble&Inertiapumps2Performance
Thesewereverycrudetests,measuringhowfastthe
pumpcouldfilla5galbucket.Theliftwasabout6feet
andthepumpcylinderextended12feetintothewell.
Theinertiapumpcouldoutputaround4gallonsper
minuteandthemarblepumpcouldoutput57gpm.
However,themarblepumpwasmuchmoretiringto
operateandrequiredtwohandsatthehighendofits
flowrange.
Pleasenote:Theseperformancevaluesreflectasingle
operatorandasinglewaterdepth.Theinertiaand
marblepumpsreactverydifferentlywhenthepumping
speedischanged,asitwouldifthewaterweredeeper
andrequiredmoreworktolift.Theinertiapump
greatlydecreasesinefficiencywhenitisstrokedslower.
Themarblepumpincreasesinefficiencyatslowerspeed
becausethereislessresistanceinthepistoncheckvalve.
Iftheinertiapumpwillbeusedatlargelifts,itshould
haveaverysmallgapbetweentherisingmainandthe
plungersothatthewatervelocityandresistanceto
reversingdirectionarehigh.
2 4
Therubbersockrippedoffofthesockpumpsometime
duringthetestsoitsresultswereinconclusive.
21
FactorsthatAffectPumpPerformance
Fluidresistanceandcavitationincheckvalves.
Checkvalvesgivealotofresistancetofluidflow.This
translatestomoreforcerequiredatthehandletomove
thewater.Furthermore,aswaterspeedsuptogo
throughthevalveorifices,itspressuredrops,eventually
reachingthevaporpressure.Atthispointitflashesto
vapor(waterboilsatambienttemperatureifthe
pressureislowenough).Whenthevaporbubbles
collapse,theysendshockwavesthroughthewater
column.Theshockwavecanburstapipe,especiallyata
Torelbow.Or,ifthevaporbubblescollapseona
surfaceinsidethepump,theysendshockwavesthrough
thatmaterialandeventuallycausepittinganderosionof
thesurface.Thisprocess,calledcavitation,isaleading
causeofdamagetopumpsandvalves.Cavitationis
moreanissueinthefootvalveofasuctionpumpthan
thepistonvalvebecausethewaterpressureisalready
lowerduetothesuctionrequiredtoliftthewater.If
cavitationisoccurringinahandpump,onesolutionis
topumpslower,reducingthevelocityofwaterthrough
thecheckvalveandthusreducingthepressuredrop.
Anothersolutionistomakethevalveorificeslarger,
achievingthesameresult.
Lengthofpiping
Thelongerthepipe,eithersuctionordischarge,the
greatertheforcesrequiredtoacceleratethewateron
eachstroke.Thediameterofthepipedoesnotaffectthe
accelerationforce3.
Pipediameter
Thesmallerthepipediameter,thefasterwatermust
flowforthesameoutput.Frictioninpipesincreases
withthesquareofvelocity4.Pipecrosssectionalarea
increaseswiththesquareofthediameter.So,halving
thediametergives1/4thecrosssectionalarea,which
givesfourtimesthevelocity,whichgives16timesthe
flowfriction.Asaruleofthumb,Isuggestthatthe
suctionpipediameterbenolessthanhalfthediameter
3Inasmallerdiameterpipe,lesswatermassisbeing
accelerated,butitbeingacceleratedtoahighervelocity.These
twoeffectscancelout.
Therelationshipbetweenflowvelocityandfluidfrictionis
complicatedforturbulentflow;Itisonlyaroughguesstosay
thatdoublingtheflowwillresultinfourtimesthefriction.
PVC Water Pumps
ofthepumpcylinder.Ideallyitwillbenolessthanhalf
thearea,whichrequiresadiameter0.707ofthepump
cylinder.Fora2pumpcylinder,use11/4or11/2 Aleathercupsealispressedagainstthecylinderwallby
suctionpipe.Ifthepipeisrunningalonghorizontal
distance,itmaybedesirabletoincreaseitevenmore.
Surgechamber
Asurgechambersmoothesoutapulsatingflowina
pipeline.Inthecaseofarowerpump,thesurge
chamberispositioneddirectlybelowthefootvalve.On
theupstroke,thepistonsuckshalfofitswateroutofthe
surgechamber,withtheotherhalfcominguptheinlet
pipe.Thiscreatesavacuuminthesurgechamberthat
pullswaterbackintoitduringthedownstrokeofthe
piston.Thus,theintermittentflowofwaterinthe
cylinderistransmittedintoamoreorlessconstantflow
ofwaterintheinletpipe.Watervelocityishalfasgreat
andthereforepipefrictionis1/4thasgreat.
Surgechamberscanalsobeusedonthepressuresideof
apump.Theybecomemoreandmorenecessarythe
longerthepipelineisandthemorewatermustbe
acceleratedoneachstroke.Withsinglepistonpumps,
theyallowuseofsignificantlysmallerdiameterpiping.
Withtreadlepumps,duetotheirtwocylinders
deliveringwatercontinually,theycannotreducepipe
diameterbutstillwillreducepressureshockstothe
pumpifconnectedtoalongpipeline.
Asaruleofthumb,asurgechambershouldhavea
volume2xthecylindervolume.Thelargerthevolume,
thesmallerthepressurevariationinthechamberand
themoresteadytheflowuptheinletpipe.Theperfect
chamberwouldmaintainaconstantpressureregardless
oftheirregularityofthepiston.
Surgechamberonarowerpump:4Sch40PVC,18long
22
Pistonsealmaterial
thepressureabovethepiston.Thiscreatesaverygood
seal,butalsosignificantfrictionifthecylinderwallis
notsmooth.PVCcylindersareeasilyscoredand
roughenedbygritthatgetstrappedbetweenthecup
sealandthecylinderwall.
Therubberdiscpistonsealdeflectsintothegaparound
thePVCsupportdiscwithincreasingpressure.This
allowssmallamountsofwatertoleakpast,increasingas
thepressureincreases.Theselossesareinsignificant
comparedtothepumpoutput,buteliminatecontact
betweentherubberandthecylinder,eliminating
mechanicalfriction.Sandinthewaterisnotaproblem
becausetherubberdiscsfoldawayfromthecylinderon
everydownstroke,flushingoutanysandthatmayhave
becometrapped.OnepumpatECHOwasusedtobail
waterfromaholeandstillfunctionedevenwithafoot
ofsandaccumulatedontopofthepiston.
DesigningaPump:Tradeoffs
Pipecost
Suctionanddischargepipewilloftenbeamuchgreater
costthanthepump.Smallerdiameterpipeischeaper,
butyouwillgetlesswaterbecausemoreenergywillbe
losttofluidfriction.Investinlargerpipe!Humanlabor
isnotcheap!Weonlyputout1/10ofahorsepower
averageoveradaysworkandwewanttomakethe
mostofit.
Pistonrodmaterial
Metalisstrongerandcanbebentbackifdamaged.
StainlesssteelandPVCaresmoothandwillnotrust.
PVCisweakbuteasytoreplace,andifabuseditwill
breakinsteadoftransferringloadstothepumpand
breakingotherparts.PVCflexesmore,allowinga
persontopullcrookedlyonthehandlewithoutcausing
alotoffrictionintherodbushing.
Checkvalves
Sideflapcheckvalveshavemuchlowerflowresistance,
buttheyareeasiertoripoffortobecomeaskewsothe
flapdoesnotfullycoverthehole.Theyalsoopen
PVC Water Pumps 23
furtherandsowhentheyclosemorewaterslipsback assembly.Valveflapscanbemadefromtiresidewallor
throughandthevalveslamsharder.Sockvalvescanrip frominnertubewithabackingdisctogiveitrigidity.
offmoreeasilythanflapvalves.Largerholesinradial
patterncheckvalvesgivelessresistancebutweakenthe
valvedisc.

OverallCost

Itisageneralrulethatthecheapestpumpswillhave
lowerflowratesandusethebodylessergonomically.
Moreexpensivepumpsarebuiltstrongenoughtouse
strongermusclesandaremorecomplexinordertouse
musclesinthemostcomfortableposition.So,themarble
pumpisverycheapandeasytobuild,butawkwardto
operateandgivesasmallflowrate.Thetreadlepump
ontheotherhandismostexpensivebutproducesfar
morewaterbyusingthelegmuscles.
AlternativeDesignsforComponents
Sideflapperfootvalve
Piston
Leathercupseal:
TheleathercupissandwichedbetweentwoPVCdiscs
witharadialholepatterncoveredbyarubbervalve
flap.Thecenteroftheleatheriscutout,leavingalip
about1/8wideforthePVCdiscstogrip.Cuttheinner
PVCdisctofittheleathercup,butsoaktheleatherfirst
forafewdayssoyouwillknowitstruedimensions.

CutthelowerPVCdisctofitlooselyinsidethepump
FootValve
cylinder.TapthePVCdiscstoreducehardware.When

assembling,lineuptheholesinbothdiscs.
Variationsontheradialholearray:

Therearemanypossiblepatternsofholesforavalve
witharubberflapboltedinthecenterofthevalvedisc.
Layoutapatternofholesappropriateforthediameter
ofthepump.Consideringthefollowing:

Thevalvemustnotcatchonthecylinderwallwhen
itopens.
Therubbermustoverlaptheholesbyatleast1/16
ortheedgewillbesuckedintotheholeandbreak
theseal.
Distancebetweenholesshouldbe1/2thehole
diametertomaintainstrengthofthedisc.Ifthedisc Leathercuppistonseal
isthickerthan1/10ofitsdiameter,thismaybe
reduced.Usegoodjudgment. RubberdiscsealwithsolidPVC:
Maximizethetotalareaoftheholes Therubberdiscpistonsealcanbeusedwithoutdrilling
Forthesametotalarea,fewerlargerholesgiveless holesinthePVCdisc.MakethePVCdiscsmaller,1.75
flowresistancethanmore,smallerholes. diameterfora2cylinder,andtherewillbesufficient
Holesneartheperimeterwillgivelessresistance waterpassagearoundthedisc.Usemorerubberdiscsto
thanholesnearthecenterbecausewatercanpush bridgethegap.(ThesquarepieceisanutcutfromPVC
therubberflapfurtheroutoftheway. sheetandtapped.)

Sideflappervalve:
Thesideflappervalveismadebyflaringand
compressingpiecesofpipetobuilduptheendofa1.5
inletpipeuntiltheendisthickenoughtoscrewavalve
flapto.The2pumpcylinderisthenflaredoverthis
PVC Water Pumps 24

Alternativehoseclamp



Rubberdiscpistonseal TestingMethodologyandData

MeasuredQuantities
Handle Handleforce(lb):mechanicaldialforcegaugebuilt
intopumphandle
PVCpistonrod: Volumeoutput(gal):57galplasticbarrel
Shapeawoodhandleandboreaholethroughthe Time(s)
center,slightlysmallerthanthePVCpipe.Heattheend Numberofstrokes:countedbypersonpumping
ofthepipeandinsertintothehole.Whencool,drill Strokelength(ft)
throughthewoodandinsertascreworpintosecurethe
rod.ThiswilllikelybestrongerthanthePVCTee CalculatedQuantities
handle. Flowrate,gallonsperminute=volume(gal)/time
(s)*60(s/min)
Workinput,horsepower(hp)=strokelength(ft)*
strokecount*handleforce(lb)/time(s)/550(ftlb/s
perhp)
Dynamicforce:subtractstaticforcefromtotalforce.

WoodhandleforPVCpistonrod
Equipment
Metalpistonrod: 2rowerpumpwithheadsealandradialstylefoot
Drillandtapaholethroughthewoodhandle. valve
borehole28feetdeep,watertableat7feet
platformtomountpump
supportsforsuctionpipeonhorizontalruntest
55galplasticbarrelwithflappervalvedrainin
bottom(holds57galtobrim)
outletpipetobarrel
handleforcegauge
timepiece

Woodhandleformetalpistonrod Procedure
ForeachtestItimedhowlongittooktofillthe57gal
HoseClamp barrel.Eyeingtheforcegaugeinthehandle,Iwasable
tomaintainaconstantaverageforceonthehandle,
Drillaholeinbothendsofametalstrap,bendintoa withinafewpounds.
hoopwithearsstickingout,andputaboltthroughthe
holes.Thisprobablyhasatightergripthanahose
clampandismoreeasilypaintedforcorrosion
protection.

PVC Water Pumps 25

1suctionpipewithsurgechamber
Force(lb) time(s) strokecount
40 178 178
30 211 181
20 315 179

1suctionpipenosurgechamber
Force(lb) time(s) strokecount
50 259 138
40 283 159
30 369 169

1.25suctionpipenosurgechamber

Rowerpumpwith27suctionpipeinborehole force(lb) time(s) strokecount
50 189 142
40 226 149
30 323 161
Testsofsuctionpipeoptions

FlapperValve,1.25suctionpipe
force(lb) time(s) strokecount

Rowerpumpwith60horizontalrunfromborehole 50 154 128
40 182 130
30 242 132
Testusingpumpwithsideflappervalveinsteadofradialvalve

norun
HandleForce Timetopump
(lb) 57gal(s)
50 196
40 252
30 299
20 480
42 225
55 189
30 297
Handleforcegauge(060lb)
20run

RawData HandleForce Timetopump

(lb) 56gal(s)
volume 57gal 40 260
strokelength 2ft 30 374
lift,vertical 7ft 45 223
inletpipe,vertical 27ft 50 200
forcepistonreturn 14lb 40 257
Fixedquantitiesforalltests 30 351
45 204
35 296

PVC Water Pumps 26

40run Examples
Convert10gallonsperminute(gpm)tolitersperhour
HandleForce Timetopump (lph)
(lb) 56gal(s)
50 224 10 gal 60 min 3.79liters 2,274l

min hour gal hr
40 309
30 366

45 230
35 301 Convert6metersofwaterintopoundspersquareinch
(psi)
60run

6m 14.7 psi 8.6 psi
HandleForce Timetopump
(lb) 56gal(s)
10.3m


50 282
40 337
30 430 Acknowledgments
45 301
35 393 Theideafortherubberdiscpistonsealandcheckvalve
Testsofhorizontalrun originatedwithMattKiehlatMessiahCollegein
2003.IlatersawasimilardesigninWayneNiles
PVCpumpdesignedinHaiti.
Appendix Theideafortherubberdischeadsealoriginatedwith
MessiahCollegestudentsworkingontheWestAfrica

PumpProjectin2001.
Imperialtometricconversions Therowerpumpinthisdocumentisinspiredbythe
MCCWestAfricaRowerPump,althoughallofthe
Conversionfactors componentsaredifferent.
1inch=25.4mm
1gallon=3.79Liters
1atmosphere=14.7psi=34feetofwater=10.3metersof
Bibliography
water5

1ft^3water=62.4lb
MCCRowerPumpconstructionmanual
1horsepower=~550footpoundspersecond=746watts
WayneNilespictorialmanualforconstructinga

PVChandpump(ECHOelectronicfiles)
Calculations
WorldVisionAustraliabrochureforconstructing
Writeeachconversionfactorasaratio(fraction).
theRusPump(EHCOpaperfiles)
Multiplyfactorstogetheruntilyougetthedesired
TerryWaller,SketchesofaPVChandpump(ECHO
dimensions.Unitscanceloutwhentheyaredividedby
paperfiles)
themselves:gal/gal=1,justlike4/4=1.
DocumentsdescribingtheCanzeePump(online)

MessiahCollegeSeniorEngineeringProjectreport,

2001:IntegratedPumpDesign

5
Pressure is defined as a force per unit area, e.g. pounds per
square inch: 1 atmosphere is the pressure at sea level exerted Contact
by the weight of the earths atmosphere. Pressure can also be
defined in terms of the weight of a column of water: A 6
meter high column of water exerts a force of 8.6 pounds per JosephLongeneckerformoreinformation:
square inch. The volume of water has no effect on the jblongen@gmail.com
pressure, i.e. a 2000 gallon tank and a two inch PVC pipe will RevisionHistory:Lastmodified25Oct.2010JBL
have the same pressure at the base if they are the same height.