Action Against Hunger (ACF ) - Uganda Mission INDIA MARK II. Installation and Maintenance Manual for Hand Pump Technicians and Borehole Caretakers

Transcription

1 Action Against Hunger (ACF ) - Uganda Mission INDIA MARK II Installation and Maintenance Manual for Hand Pump Technicians and Borehole Caretakers ACF - WASH September 2010

2 About this Manual This Manual is prepared by the Water, Sanitation and Hygiene (WASH) department of Action Against Hunger (ACF) to facilitate boreholes sustainability. This manual is not a standalone document but can be used with other operation and maintenance related documents. Who is this manual for? This manual is prepared as an elementary guide for Hand Pump Technicians that are involved in the major and minor repairs of hand pumps in a community. It is also a useful guide for care takers who are from time to time required to carry out preventative maintenance work on the borehole/water point. Action Contre la Faim - International Network (ACF-IN) is a professional Non-Governmental organization (NGO) involved in the fight against hunger. It operates in four technical areas: nutrition and health, food security, water, sanitation and hygiene (WASH) and advocacy in order to help the most vulnerable populations regain their food autonomy as means to life without dependence on external help. In the Uganda Mission, there are programmes being implemented in Acholi and Lango Regions (Food Security, Nutrition & Health, WASH), and Karamoja region (Food security, Nutrition & Health and recently WASH). Across Northern Uganda where ACF operates, deep borehole wells are the most reliable and secure source of clean water for people. These simple and inexpensive technologies have revolutionized the way people in developing countries access water. Borehole wells allow people to tap into groundwater that is not accessible from the surface, as well as minimize the contamination of the water by surface pollutants by keeping it in a closed system until it reaches the spout. Borehole hand pumps use human power and mechanical means to move water in a one-way direction using a system of suction and discharge valves. The most common model of pump used in the region is the India Mark II hand pump originally manufactured in India by Apex Press. 2

3 The Role of the Pump Mechanic They are expected to render technical assistance to the community in maintaining their hand pumps Regularly inspect boreholes functionality status at least once or twice every month He/she should discuss with the WSSC issues pertaining BH status During every inspection, necessary servicing (preventive maintenance) should be done Ensures that the pump spares selected can give lasting solution to the existing problems Maintain tools and a stock of spares to enable him/her to have a capacity to carry out repairs during routine maintenance visits and when called for hand pump repairers The India Mark II Pump Major Components The Handle Assembly This is a long lever, which is connected to a piston in the pump (Pump Cylinder) that draws water up to the tap (spout). A longer hand lever can more efficiently draw water from a deeper well with fewer strokes. The Pedestal This is the outside main body of the borehole, protection the parts inside. The Water Tank Assembly This is the part where water from the pipes collects before it goes out through the spout. It is where the rising main is connected using thread in the riser pipe holder. The Pump Head Assembly This houses many of the mechanical components of the borehole handle, including the pump-lever, chain, upper connecting rods, and the pivot. Connecting Rods and Rising Mains These pieces usually come in 10 feet lengths and are threaded with male and female sockets to allow for connection for variable well depths. Connecting rods are attached to the pump cylinder. This drives the pistons which draws water from the well. Riser pipes are usually 11/2-inch (40mm) diameter pipes that carry water up to the spout. Pump Cylinder This is the main pump, which is set in the aquifer deep underground. Includes the plunger rod, upper and lower valves, rubber seating and sealing rubbers, brass liner, reducer caps and cylinder body. The depth that a pump is set is based on the desired yield rates. A minimum yield of 1-2 cubic meters per hour is usually targeted. One cubic meter is equal to 264 gallons. 3

4 The Hand Pump Detailed Assembly Cover bolt washer Axle washer, nut & check Chain bolt & nut Maintenance Cover Bearing Head Assembly Handle Assembly Chain Coupling Chain Connecting Rod Check Nut Guide Bush Water Tank Assembly Riser pipe holder Bolt, nut, washer & check nut Pedestal Platform Leg PVC Casing Pipe Riser Pipe Connecting Rod Figure 1: Above ground parts of the India Mark II borehole assembly. The below ground details are not included here but will be illustrated next page, in Figure 2. 4

5 Below Ground Pump Cylinder Figure 2: Pump cylinder for the India Mark II. This is the pump cylinder, which is set in the aquifer deep underground. The depth that a pump is set is based on the desired yield rates (flow rates). A minimum yield of cubic meters per hour is usually targeted. One cubic meter is equal to 1000 liters. 5

6 How Boreholes Hand Pumps Break Down Hand pumps, like all mechanical assemblies tend to break down if not properly used, neglected, or if overused. Long-term maintenance of rural water boreholes therefore has become the most challenging task for governments and humanitarian aid organizations. In response to this, ACF will work with beneficiaries to educate communities on proper maintenance schedules for community boreholes. Common mechanical borehole problems include: Worn out handle assembly that is no longer properly connected to the chain and connecting rods Worn out bearings and bolts components in pump head assembly Worn out pipes and leakage of the pipes. Worn out sealing and rubber sealing rings Riser pipes become corroded and disconnected. Broken pedestal which can create unsanitary conditions inside the well How boreholes can be maintained: Ideally, a well is regularly checked and maintained by a trained pump mechanic whose duties are to make sure major breakdowns do not occur, which could severely interrupt service. This includes preventative maintenance to ensure a long life for the borehole. A typical schedule of maintenance could involve the following: Daily Monitor pump operation and grease pump parts where necessary Check for all loose nuts and tighten them when necessary Avoid banging the borehole with the handle when pumping water Fix any broken fencing (to keep animals out) and ensure that water point is clean Weekly Lubricate all joints and moving parts of the borehole Check and tighten all nuts and bolts Check security of pump on pedestal Monthly Check output rate Check for condition of concrete apron Yearly Remove the pump cylinder and pipes from the well, inspect, replace any worn out parts. 6

7 The tool set for maintaining the India Mark II Pump (Refer to the U2 and U3 installation manuals) Tool Use Picture Pipe/rising mains For lifting or lowering the lifting spanner rising mains Pipe vice, self locking clamp For holding the pipes firm when tightening or loosening pipes, and when cutting the threads of the rising mains Fixed/open ended spanner 17 x 19 (mm) For connecting rod couplings, tightening and loosening bolts and nuts Crank (axel rod) spanner 17 x 19 (mm) For tightening and loosening the chain, bolts and nuts Connecting rod vice For holding the connecting rods Pipe Die For cutting threads in the galvanized pipes Connecting Rod Die For cutting threads in the connecting rods Bearing pressing tool For fixing bearing Hack saw For cutting pipes and rods 7

8 The tool set for maintaining the India Mark II Pump (Refer to the U2 and U3 installation manuals) Tool Use Picture Rod lifter For lifting and lowering the rods File Hammer ball point For filing the top of connecting rods after cutting For driving out/in the handle axle bolt. Pipe wrenches (600mm)or (450mm) Handle axle punch. For tightening/enlightening of the rising mains during installation or dismantling of the pump. Used to drive out the handle axle bolt without damage to the threads. A center punch Oil can ¼ litre Used to remove the broken ball bearing from the bearing housing. For cooling during cutting of treads. Steel brush Used for brushing/ cleaning the threads cut. Coupling spanner Used for holding firm the Nuts/ bolts when tightening or loosening Chain supporting tool Provides support to the chain Screw driver For screwing the bolts for the button dice. 8

9 Repair and Rehabilitation Procedures For installing or dismantling a borehole, at least two trained people are required to oversee and guide the unskilled labour force. The technicians should ensure that they have a complete tool box with all the required tools for installing / dismantling including an extension rod of about 30-50cm length. Various steps and tools are used for each step as illustrated in the U2-installation manual, which is expected to be in the training package (and beyond the scope of this training). The Roles of the Water User Committee in ensuring the functionality of the Water Point Mobilize community members to participate in water source protection e.g. Building the fence, and regular cleaning of the surrounding. Keep an updated list of the water users in the community. Collect and keep contributions towards the construction cost and the O&M funds Regularly visit and monitor the condition and performance of the water point Verification of the purchase of materials needed for the repair or maintenance of the water source. Pay for any repairs carried out by a mason or hand pump mechanic. Supervise and provide support to the water source caretakers. The Roles of the Caretakers Show people how to use the water point properly Carry out regular maintenance of the water point e.g. sweeping and slashing around the borehole. Keeping record of all the maintenance work carried out on the source either directly by the caretaker or by a (HPM) Hand Pump Mechanic, plumber or mason. Mobilize community members to participate in maintenance activities e.g regular cleaning of the surrounding of the water source, advice the community on regular cleaning of containers both for storage and collection. 9

10 The Standard Tools Required By a Community Hand Pump Mechanic 1. Button die to suit M12 x 1.75 threads 1 No. 2. Die set for 32/40mm N.B pipe 1 set mm pipe wrench 2 No. 4. M17 x M19 double ended spanners (10mm x 12mm) 1 No mm pipe wrench 2 No. 6. Screw Driver 300mm long 2 No lb (ball Point Hammer) 1 No. 8. Hack saw frame and blade (300mm) 1 No. 9. Pressure type oil can (½ pint of oil) 1No. 10. Wire brush 1 No mm half round file with handle 1 No mm flat file with handle 1 No. 13. Graphite and Lithium Grease 1 can 14. Adjustable spanner 1 No. 15. Nylon Rope (4 strung) 75 metres General Maintenance Guidelines The India Mark II deep well hand pumps are to be properly maintained to ensure safe potable drinking water to the community, without break down. Proper and regular maintenance will prevent breakdowns as seen earlier in the booklet. The moving parts in the India Mark II hand pump above and below the ground level are few and therefore simplifying the maintenance of the hand pump. The following schedule of maintenance has been drawn at fixed intervals and has been explained more elaborately. 1) Once in 30 days: (i) Tighten the handle axle nut and lock nut (ii). Look for loose or missing flange bolts and nuts (iii). Open the front of the head cover and clean inside the pump. (iv) Check the chain anchor bolt for proper fitment. Tighten if necessary. (v). Clean the chain assembly. Apply graphite grease. (vi). Look for rusty patches and clean them. (vii). Check whether the hand pump base is lose in the foundation. In case it is loose an arrangement should be made to redo the foundation. 10

11 2) After 365 days (1 year) (a) Examine the pump carefully and check whether: (i) Discharge is satisfactory (ii) Handle shaky and not firm (iii) Guide bush has excessively worn out (iv) All bolts, nuts and washers are in position (v) Chain has worn out (vi) Roller chain guide is excessively worn out (b) Overhaul the pump and follow the instructions: (i) If chain, bearing spacer are damaged, replace them (ii) If roller chain is badly worn out, replace the handle assembly (iii) If there are any damaged pipes have them replaced (iv) Open out the cylinder assembly and replace cup washers, sealing rings and other components found to be faulty (v) Check the condition of the water tank riser holder. If the threads are worn out, replace water chamber (vi) Check for any other seam line failures or cracks (vii) Re-install the pump as in the training 11

12 PRICES OF SOME OF THE MAJOR BOREHOLE SPARES PARTS No. Item Unit Price (UgX) 1 Pump Head Complete 150,000 2 Pump Handle 90,000 3 Chain 15,000 4 Ball Bearing 25,000 5 Water Tank 90,000 6 Cylinder Complete 250,000 7 Head Bolts 1,000 8 Head Nuts 1,000 9 Sealing Rings 2, Upper Valves Complete 20, Pump Buckets 3, Pipes 50, Connecting Rods 20, Lower Valves 20, Axle Bolts 7, Axle Nuts 1, Bearing Spacer 1, Washer 1, Chain Bolts 1, Chain Nut 1, Pedestal 150, Reducer Cap Plunger Rod 20, Rubber Seal (lower) 1, Rubber Sela l (upper) 1, Sockets 2,000 12

13 S/ N THE TROUBLE SHOOTING TABLE FOR COMMON PROBLEMS SIGN/DEFECT/INDICATION POSSIBLE CAUSE(S) REMEDY 1 Draws rusty water Pipes and the rods corrosions Chemistry of water problems Free the pipes and rod from corrsion by developing/flushing the well. 2 Pumped out water containing worms 3 Pump weightless and no water Then at instant of breakdown splash sound hardly. Damaged casing Improper sanitary seal Poor well design Pipes/rods disconnected and dropped. Chlorinate the well Improve on the BH design. Check for the pipes if the pipes are dropped then Fishing out is required. 4 Pump weight is usual but no water comes Reducer cap disconnected and the lower valve assembly dropped. Complete cylinder dropped. Cylinder yoke body disconnected Dismantle and replace the lower valve and the reducer cap. Replace the whole cylinder. Dismantle and reconnect it. 5 Pump is very light but no water comes completely Disconnection of rods at the joint Re-connect the disconnected rod. 6 Water takes very long to come even after a brief stop over. Worn out sealing rings or pump buckets Cracks on the rising mains Replace the sealing rings and the pump buckets. Replace the damaged rising mains 7 Water only comes well during rapid pumping Pipe leakages Worn out sealing and rubber sealing rings Replace leaking pipes or tighten the pipes at the sockets. Replace sealing rings 8 Unusual noise when pumping Lack of lubrication Bearing crushing Some Bolts and nuts are missing or loosen Top connecting rods is bent 9 Muddy or silt water pumps out Cylinder is too close to the well bottom Insufficient filtration of inflow water by the gravel packs. Greasing Replace bearing Tighten the nuts or replace the missing nuts. Remove and straighten the rod or replace the rod. Reduce the cylinder depth depending on the yield of the well, cylinders shouldn t be installed at least 6m from the bottom of the well. Develop the well. 13