Career Episode -3a) IntroductionCE 3.1My Third career episode is based on my project ‘THE DESIGN AND INSTALLATION OF WINDMILL POWERED WATER PUMP’. The project was initiated by me when I was doing my B tech in Mechanical Engineering. The project duration was 3 month and carried out from March 2011 to June 2011. The project was carried out for the partial fulfilment of the requirements for the award of the degree of Bachelor of Technology. The project was based in my college, Toc H institute of Science and Technology Kochi, India.BackgroundCE 3.2Toc H Institute of Science and Technology is one of the leading professional college in the country affiliated to Cochin University of Science and Technology. The project was carried out in the campus of Toc H Institute of Science and Technology. In household electrical consumption a lion’s share of the usage goes for pumping water from the well to storage tanks. The water pump is a high power consuming machine and if the conventional water pump can be substituted with a wind mill water pump a good amount can be saved on the monthly electric bill. Wind mills are a non-conventional source of producing power and it is considered as one of the most potential source of energy. The aim of my project was to design, fabricate and install a wind mill as a source of generating power for running a water pump. CE 3.3I have performed the following tasks during the project;• Studied and prepared a project synopsis.• Planned the project for timely completion.• Designed the entire system and prepared necessary mathematical calculations. • Prepared the cost estimation for fabrication and installation.• Prepared a block diagram of the system using AUTOCAD• Purchased the materials after detailed research.• Inspected the fabrication processes.• Coordinated with civil department regarding the construction of foundation.• Controlled the installation of the system and conducted trial run.• Conducted regular project meetings with the project guide and the team • Developed detailed project reportCE 3.4Below is the hierarchy of the project with clear demonstration of my position; c) Personal Engineering ActivityCE 3.5I started the project with a detailed study about wind mills and its components, water pump and other components. A detailed study was conducted on the availability of wind and power that can be trapped by wind mills. After initial study, I prepared a synopsis indicating the objectives, components to be used, expected power generation and estimated cost. This has been then submitted for the approval of Department head and project guide along with the project planning draft. After the approval I proceed further towards the design of the system. CE 3.6I designed the system consists of a high solidity multi-vane wind rotor, drive shaft, crank, connecting rod and a reciprocating pump. Rotary motion of the windmill rotor is translated to reciprocating motion of the connecting rod by the crank. The connecting rod operates the pumps piston up and down through the cylinder during its strokes. Two check valves, both opening upwards, are fitted on the piston and the bottom of the pump. These valves allow the flow only in upward direction. When the connecting rod drives the piston in the upward direction, the piston valve is closed and thus the water column above the piston is lifted up, until it is delivered out through the discharge line. At the same time, suction is created below the piston, which causes the suction valve to open and thus fresh water from the well enter into the space below. During the downward stroke, the piston valve is opened and the suction valve is closed. The water collected below the piston thus enters into the space above, through the piston valve. These cycles are repeated resulting in pulsating sinusoidal water discharge from the system.CE 3.7The main difficulty faced during the design was the design of blades. Just like an aeroplane wing, wind turbine blades work by generating lift due to their shape. The more curved side generates low air pressures while high pressure air pushes on the other side of the aerofoil. The net result is a lift force perpendicular to the direction of flow of the air. The dimensions of blades were fixed after calculating the power required to run the pump. The required suction head and delivery head of the pump is taken into account to calculate the power input required for the pump. Then I calculated the required diameter of the wind mill turbine. The pump chosen was a reciprocating pump since its efficiency is more compared to centrifugal pump; Reciprocating pumps utilize the principle of a moving piston, plunger, or diaphragm to draw liquid into a cavity through an inlet valve and push it out through a discharge valve.CE 3.8Then I calculated the dimensions of the drive shaft, which is to be used to carry the power produced by wind mill to run the pump. The dimensions were calculated by taking the expected load on the shaft account. After the design of components, I prepared a block diagram of the system indicating the dimensions using AUTOCAD. Then I formed a team for fabrication with experts from the field of welding, molding. The material requirement was calculated with the help of an expert team and purchased ensuring the quality. I arranged all the tools and equipment’s before the beginning of fabrication and ensured the availability of required labor force. A planning was drafted for the fabrication and installation process and it was aimed to complete within 45 days. CE 3.9The fabrication was started by molding the turbine blades as per the design. The location for the wind mill was already selected as per the flow of wind. I consulted with the civil department for the construction of foundation for the wind mill. Then the components of the wind mill are joined together by welding. The pump was erected at a concrete platform. The drive shaft was fabricated in a local workshops and it is then connected both to the wind mill and pump through slider crank mechanism. I consulted with senior engineer of a contracting firm for practical solutions throughout the installation process. CE 3.10After installation, I performed detailed inspection and checked the position of all the mechanical components. Then I consulted with my project guide and department head and fixed a time for the trial run. During the trial run, all the people worked behind the project were present. I controlled the trial run and ensured safety. The trial run was a success and the system worked as desired. CE 3.11The main difficulty faced during the installation was to ensure the proper joining of components. I ensured it by careful inspection and declared that the entire system is strong and safe. A team of experience in installing heavy equipment helped me a lot in finding practical solutions to problems raised. I monitored the precautions to be taken care during fabrication and installation. I ensured that the workers are strictly following the safety principles and using the safety equipment’s when ever required. CE 3.12Another difficulty was to build a strong foundation for both the wind mill and pump. This is essential since the machines are vibrating while working. The civil engineering department helped me on this and they designed and built strong foundations. CE 3.13This project was a challenging one and I was able to make it a success. This is achieved as a result of detailed background study, well coordination with other departments and above all with the dedication of my team. I applied the knowledge gained from my studies especially from the workshops and practical sessions. My knowledge in the field of design of engineering components, fabrication processes, engineering drawing, material planning, working of different machines and practical knowledge on installation helped me to accomplish my aim. My department head and project guide was with me every time and provide advice and suggestions. CE 3.14I prepared a detailed project report after the success of my project. I drafted the literature survey, specification and working of machines used, overall processes, challenges faced and solutions implemented, design calculations, drawing, cost analysis, suggestions for improvements, critical findings and recommendations for maintenance and photos. The purchasing of materials and other expenses were through proper channels. In addition to the evolution of a successful design for using a non-conventional energy source, the project days were helpful in building me especially by enhancing my engineering knowledge. d) SummaryCE 3.15My aim was to build a wind mill powered water pump that can be installed for Household purposes. I express my humble gratitude to my Department head, college authorities, project guide and my entire team who inspired and helped me to make this project a success. I system will be an environmental friendly system and can be adopted by households and for irrigation purposes. Wind power can be utilized profitably over conventional electric motor pumps or can be used in remote areas with no electric supply where sufficient wind availability is there.