This document describes the fabrication of a pedal operated water pump submitted as a project for a diploma in mechanical engineering. It includes sections on the construction details, working principle, spare parts drawings, introduction to pumps, applications, advantages and disadvantages, features of the project, safety, care and maintenance, painting and finishing, cost estimation, and conclusion. A group of 6 students fabricated the water pump under the guidance of their professor as part of their studies.

1. FABRICATION OF PEDAL OPERATED
WATER PUMP
Submitted in the partial fulfillment of the requirement for the award of
“DIPLOMA IN MECHANICAL ENGINEERING”
SUBMITTED BY:
1. G.JAGADESH KUMAR 4. M.G.VISHNU
2. R.GOPINATH 5. D.MUTHUKUMARAN
3. T.NARESH 6. K.MANI
Under guidance of
Mr. Z.KHAJA MOIDEEN ,B.E
MARCH 2013.
DEPARTMENT OF MECHANICAL ENGINEERING.
SRI DURGA DEVI POLYTECHNIC COLLEGE
RSM NAGAR, KAVERAI PETTAI.

2. SRI DURGA DEVI POLYTECHNIC COLLEGE
RSM NAGAR, KAVERAI PETTAI
BONAFIDE CERTIFICATE
This is to certify that this Project work on
“FABRICATION OF PEDAL OPERATED WATER PUMP ”
submitted by …………………… ……………. Reg. No. ……………
in partial fulfillment for the award of
DIPLOMA IN MECHANICAL ENGINEERING
This is the bonafide record of work carried out by him under our supervision
during the year 2013
Submitted for the Viva-voce exam held on ……………..
HOD PROJECT GUIDE
INTERNAL EXAMINER EXTERNAL EXAMINER

3. ACKNOWLEDGEMENT

4. ACKNOWLEDGEMENT
At the outset, we would like to emphasize our sincere thanks to the
Principal Mr. K.LAKHSMANAN,M.E encouragement and valuable
advice.
we thank our Esquired Head of Department Mr. S.JESUDASS M.E for
presenting his felicitations on us.
We are grateful on our Entourages Mr. Z.KHAJA MOIDEEN B.E,
for guiding in various aspects of the project making it a grand success.
We also owe our sincere thanks to all staff members of the
Mechanical Department.
Ultimately, we extend our thanks to all who had rendered their co-
operation for the success of the project.

5. CONTENTS

6. CONTENTS
1. INTRODUCTION
2. SYNOPSIS
3. CONSTRUCTION DETAILS
4. WORKING PRINCIPLE
5. SPARE PARTS DRAWING
6. INTRODUCTION TO PUMP
7. APPLICATION
8. ADVANTAGES AND DISADVANTAGES
9. FEATURES OF THIS PROJECT
10. SAFTY,CARE AND MAINTENANCE
11. PAINTING AND FINISHING
12. COST ESTIMATION
13. CONCLUSION
14. BIBLIOGRAPHY
15. PHOTO VIEW

7. INTRODUCTION

8. INTRODUCTION
This is a self – assessment test on the part of the students to assess his
competency in creativity.
During the course of study, the student is put on a sound theoretical
foundation of various mechanical engineering subjects and of course, to a
satisfactory extent. Opportunities are made available to him to work on
different kinds of machines, so that he is exposed to various kinds of
manufacturing process.
As a students learn more and more his hold on production technology
becomes stronger. He attains a stage of perfection, when he himself is able
to design and fabricate a device.
This is the project work. That is the testimony for the strenuous
training, which the student had in the institute. This assures that he is no
more a student, he is an engineer.
This report discuses the necessity of the project and various aspects of
planning , design, selection of materials, fabrication, erection, estimation and
testing.

9. SYNPOSIS

10. SYNOPSIS
Hand operated pumps are widely used in
domestic, industrial and commercial applications. The capacity of
this pump varies from 5 feet to 50 feet . higher head pumps are
used for pumping drinking water in villages.
Working principle;
This pump consists of one cylinder , piston two numbers of non
return valve and hand lever. When lever is raised , the piston inside
the cylinder moves down into the cylinder causes water is sucked .
when the lever is lowered or pressed down , the water inside the
cylinder discharged to outlet point.
The pedal is rotated by the foot and hence crank rotates causes the
connect rod oscillated to the lever of the pump . Thus the water is
discharged to the outlet by pedaling the cycle pedal.

11. OBJECTIVE

12. OBJECTIVE;
To lift the water from the ground floor to first floor of the domestic
building and to avoid the painstaking staircase pot carrying option.
To save the electricity

13. DEFINITION OF PROBLEM

14. DEFINITION OF PROBLEM;
During summer season , due to water scarcity problem the people
purchasing the water from lorry by collecting the water through their
pots. These pots are carried by the men or women and getting tired when
carrying water through staircase step those who are living in flat system.
When this unit is installed in first floor of the building , the suction pipe is
put in to the water delivery pipe of lorry and water is delivered through
the flexible pipe to the required collecting point by pedaling this unit.

15. SCOPE OF THE PROJECT

16. SCOPE OF THE PROJECT;
 The outstanding advantage of water discharging system from the ground floor to
first floor or discharging the water from the lorry to the collecting point by
simply pedaling this unit .
 The water is carried by the flexible tube relieves the stress free painstaking
water carrying through the pot while in staircase walking.
 Simple construction and less effort and costless maintenance and anybody can
work this unit.
 Operation is very smooth and in this system we can get more output by applying
less effort.

17. PROJECT PLANNING

18. PROJECT PLANNING
CONCEPT OF THE PROJECT
Before starting every project its planning is to be done. In a planning
functions are life the functions of nerves in our body. Planning a project is a
very important task and should be taken up with great care as the efficiency
of the whole project largely depends upon its planning, while planning a
project each and every details should be worked out in anticipation should
be carefully considered with all the relative provisions aspects.
PROJECT CAPACITY
The capacity of the project must be decided considering the
amount of money which can be invested. The availability of material and
machines and usefulness of the project.
DESIGN AND DRAWING
Having decided about the project to be manufactured at must be
designed. Design work should be done very considering all the relevant
factors.
After design the project detailed drawing are prepared. Detailed
Specification for raw material and finished products should be decided
Carefully along with the specification of the machine required for the
manufacture.

19. MATERIAL REQUIREMENTS
The list of material required for manufacture is prepared from
the drawing. The list is known as “Bill of materials”. Availability of these
materials is surveyed and purchased from the market.
OPERATION PLANNING
Next work of planning is to “select the best method” manufacture
the product, so that the wastage of materials, labor, machines and time can
be eliminated by considering various methods. The best method is to be
selected for fabrication and other works.
The proper method and proper person and the purposes of operation,
necessity operation, proper machine planning. The best method is the
developed and is applied to fabricate the project.
MACHINE LOADING
While planning proper care should be taken to find the machining
time for the operation as correct as possible. So that arrangement of full use
of machines can be made and the machine loading program can be decided.
PURCHASE CONSIDERATION
It is difficult to manufacture all the components needed for the
project in the machine shop. In each case, we should decide whether to

20. make or buy about a particular item. It is decided during the planning after
making a complete study of relative merits and demerits.
EQUIPMENT PROCEDURE
Results obtained from “operation planning” and machine loading
help in calculating the equipment require Specification of the equipment
should be laid down by considering then drawings. Drawings will also help
in deciding the necessary requirement of tools and accessories.

21. CONSTRUCTION

22. CONSTRUCTION
The project consist of
1. Hand operated pump
2. M.S. . Stand
3. CONNECTING ROD
4. Crank shaft
5. Pedal with shaft
6. Seat
M.S.Stand;
This unit fabricated in M.S. square tube of size 25 x 25 mm and
having thickness 1.8 mm .the operator can pedaled in sitting
position and this seat is elevated to a height of 400 mm at right
side of stand. The pump unit is fitted at the right side of the stand .
the pedals are welded between the seat and pump at the base stand.

23. Connecting rod ;
The connecting rod is used to connect the pump piston and the
crankshaft.this connecting rod is made in mild steel material
having 10mm square rod to a length of 450mm.
Crankshaft;
The purpose of crankshaft is convert the rotary motion into
linear motion . here the crankshaft is made in M.S. Flat of 25mm x
6mm and rotated in pair of sleeve bearing hub on the top of the
base stand. On the other end of the crank foot pedal rod is
connected and the leg is supported on pedal shown in below figure.

24. BICYCLE PEDAL ;
A bicycle pedal is the part of a bicycle that the rider pushes with their foot
to propel the bicycle. It provides the connection between the cyclist's foot
or shoe and the crank allowing the leg to turn the bottom bracket spindle
and propel the bicycle's wheels. Pedals usually consist of a spindle that
threads into the end of the crank and a body, on which the foot rests or is
attached, that is free to rotate on bearings with respect to the spindle.
Pedals were initially attached to cranks connecting directly to the driven
(usually front) wheel. The safety bicycle, as it is known today, came into
being when the pedals were attached to a crank driving a sprocket that
transmitted power to the driven wheel by means of a roller chain

25. 1.HAND OPERATED PUMP

26. Hand operated pumps are widely used in domestic, industrial and
commercial applications. The capacity of this pump varies from 5
feet to 50 feet . higher head pumps are used for pumping drinking
water in villages..
The Mark II is a closed-cylinder pump. The cylinder brass-lined
cast iron with the foot valve and piston assemblies made of
brass. The piston seals are double nitrile rubber cup seals.

27. As you can see in the figure below, the top and bottom of the
piston cylinder are “capped” with threaded reducers. The
diameter of the pump cylinder is larger than the diameter of the
riser main to which it is attached.
Maintenance on any part of the pump cylinder requires that the
riser main and the pump rod be removed from the ground.
The pump rod is galvanized steel and sections are threaded
together.

28. The pump cylinder is threaded onto the last section of riser main
and is removed in its entirety as the last component to come out
of the ground.
The pump cylinder can then be unscrewed from the riser main.
The top and bottom caps can be unscrewed from the cylinder
body to gain access to the foot valve, the piston valve, the piston
seals and anything else inside the cylinder body.
The Mark II water hand pumps are reliable and widely used.
However, for installation and maintenance, tools and skills are
required that may not be available at the village level.
As such, the Mark II is not considered a VLOM pump. It usually
requires a trained area technician to install and maintain a Mark
II pump.
The Mark II hand pump consists of the above-ground mechanism
which includes the pump head, pump handle, water tank, and
pump stand assemblies.
The below-ground mechanism includes the riser main, pump rods
and pump cylinder assembly.
The above-ground mechanism is constructed of welded steel
plate for strength and is hot-dip galvanized for corrosion
resistance. These parts may be locally manufactured.

29. A chain and quadrant mechanism of the pump handle provides
easy and accurate alignment of the connecting rod (see
illustration).
The pump handle has a high mechanical advantage. It is heavy
and is designed to counter balance the weight of the connecting
rods to reduce the pumping effort required from the user.
The handle pivot assembly (sealed ball bearings on a stainless
steel axle) makes operation easier and lowers maintenance
needs.
The pump rods are made of cold drawn bright steel bar with
threaded end couplers, electro-galvanized against corrosion.
Stainless steel rods are also available.
The pump cylinder is made from a cast iron casing with a
polished brass liner and gun metal plunger and check valve
components.
Seals (pump buckets, valve seals and cap seals) are available in
environmentally safe Nitrile rubber.
This pump can be easily adapted for shallow well, windmills and
motorized operations with minor modifications.
How Does a Hand Water Pump Work?
1. The Old Days

30. o Many older homes and farms have utilized the manual
hand water pump. The cast iron housing would bring water to
the surface from a hand-dug rock-lined well. It may have
taken many strokes from the long lever in order to gather just
a gallon of water from the underground source. Although the
manual hand pump may be of an old design, many are still in
use today for wells that are no deeper than 20 to 30 feet in
depth.
Leather
o The round interior of the manual water pump uses a metal
disc that is sealed against the smooth sides of the pumping
chamber. Generally, two discs are used that sandwich a
piece of leather. This leather creates a seal so a suction can
be created inside the chamber. As the handle is "pushed"
downwards, the lever action draws the disc and leather
sandwich up. The upward movement of the disc "sucks" the
liquid into the pumping chamber. When the handle is pulled
upwards the opposite lever action on the disk then forces the
water out of the chamber through a spout located at the top
of the hand pump. Generally, one full cycle of the hand
pump, a single stroke of up and down, may eject only one
glass full of water.
Check Valve

31. o A check valve or a one-way valve is generally used to
keep the suction pipe full of water. The check valve is located
at the bottom of the pipe and inside the well. This suction
pipe is attached to the bottom of the hand pump and is what
conducts the well water to the surface. If a check valve is not
used, the water that in the pipe can drain back into the well.
In order for the hand pump to be used, it must be kept in a
closed circuit of water. If air is allowed to enter the pumping
chamber it must be removed by priming the pump. Priming
the pump can be achieved by filling the pump chamber and
perhaps even the suction pipe with water. This can be
accomplished by pouring water through the exit spout of the
hand pump while stroking the handle up and down. This will
allow the water to fill in the chamber and suction pipe to
remove any unwanted air.
Still In Use
o Many homes in rural areas that use a private well for their
source of water may still employ a hand pump as a backup
device. These reliable pumps can be attached mechanically
to a small windmill or a solar powered motor and be used as
an emergency backup whenever the electrical power may be
disrupted. Even with modern technology, the same basic
design is still used today in the construction and operation of
a manual hand water pump.

32. 2. BEARINGS;
A bearing is a machine element that constrains relative motion between
moving parts to only the desired motion. The design of the bearing may, for
example, provide for free linear movement of the moving part or for free
rotation around a fixed axis; or, it may prevent a motion by controlling the
vectors of normal forces that bear on the moving parts. Bearings are
classified broadly according to the type of operation, the motions allowed, or
to the directions of the loads (forces) applied to the parts.
A journal bearing consists of an approximately cylindrical body around a
rotating shaft. This journal bearing is used either for supporting a radial load,
or simply as a guide for smooth transmission of torque. Most common
applications of bearings are the plain circular bearings type (with a 360
degrees arc). Lubrication usage, on the other hand, range from a simple inlet
hole to axial, circumferential, and helical grooves for efficient lubrication
distribution.
The plain bearing applications include reciprocating sliders, rotating or
oscillating cylindrical members sliding in annular sleeves, and rotating or
rotationally oscillating disks sliding on mating disks.

33. The advantages of plain bearings are as follows:
- lower first cost
- simple design
- small radial space required
- quiet operation
- not so sensitive to dust or grit
- less likely to be subjected to fatigue failure
- easy to replace
Materials:
Plain bearings must be made from a material that is durable, low friction,
low wear to the bearing and shaft, resistant to elevated temperatures, and
corrosion resistant.

34. #Babbitt (metal)
#Bronze
#Graphite
#Plastic-Solid plastic plain bearings are now increasingly popular due to
dry-running lubrication-free behavior. Solid polymer plain bearings are low
weight, corrosion resistant, and maintenance free.

35. 3. Crank rod;
CRANK is a mechanical number. It is connect to the
through follower .Links to hand lever for pump. The crank is
rotated by the cycle pedal . . When the cycle pedal is rotated, the
rotory motion of crank is converted to reciprogating motion of
connecting rod
3.FRAME STAND
First of all the frame is designed and The base is constructed
by using the welded joints and cut the material with the required
size by using hacksaw machine.
The stand frame material is used to mild steel at low cost is
widely and is used

37. WORKING
PRINCIPLE

38. WORKING PRINCIPLE
The project consist of
1.Hand operated pump
2.M.S. . Stand
3.CONNECTING ROD
4.Crank shaft
5.Pedal with shaft
6.Seat
1.HAND OPERATED PUMP
Hand operated pumps are widely used in domestic, industrial and
commercial applications. The capacity of this pump varies from 5
feet to 50 feet . higher head pumps are used for pumping drinking
water in villages.

39. Working principle;
This pump consists of one cylinder , piston two numbers of non
return valve and hand lever. When lever is raised , the piston inside
the cylinder moves down into the cylinder causes water is sucked .
when the lever is lowered or pressed down , the water inside the
cylinder discharged to outlet point.
The pedal is rotated by the foot and hence crank rotates causes the
connect rod oscillated to the lever of the pump . Thus the water is
discharged to the outlet by pedaling the cycle pedal.

40. SPARE PARTS AND
ASSEMBLY DRAWING

41. ADVANTAGES

42. ADVANTAGES
1. Single person is enough to operate this efficiently to pump the water
from the sump..
2. Easy and efficient handling of this unit without wastage of water or
damage to unit, pump and to any other parts.
3. low maintenance cost and life of equipment also increased..
4. Least maintenance of the equipment.
5. Need not require any individual work place.
6. Can be worked in the work spot.
7. Suited for pumping water for 15 feet to 20 feet depth .

43. DISADVANTAGES

44. DISADVANTAGES
• Manual power required to operate .
• The time taken for discharging the water is more when
compared to power unit.
• It cannot be used for more than 50 feet depth ...

45. APPLICATION

46. APPLICATIONS
1.By using this device , the water can be pumped up to 20 feet height.
2.used as exercise kit.

47. PAINTING AND
FINISHING

48. FINISHING AND PAINTING
JOB PREPARATION
Before welding, remove any bend in the L angle with the sludge
hammer on the anvil block. Then it is cut to the required length with the
hacksaw blade and fabricated to required dimensional shape with arc
welding.
FINISHING OPERATION BEFORE PAINTING
After welding, any slag on the welded area is removed with the
chipping hammer and cleaned with the metal wire brush. Then all the
surfaces are rubbed with the emery sheet.
Metal primer is applied on the surfaces with the brush. After drying the
metal primer, the second coating is applied with the paint.

49. SAFETY,CARE AND
MAINTENANCE

50. SAFETY,CARE AND MAINTENANCE
Before using the machine, some of the points to be noted for safety purpose,
1. Before starting the operation, check the following items
(1) Check the mechanism for proper operation .
(2) Check the alignment of piston in the unit.
(3) Don’t insert the any material or object between the during
operation of pumping.
(4) Check the leakage of water and pipeline in the unit.
(5) sit carefully while pumping the water .

51. FEATURES OF THIS PROJECT

52. FEATURES OF THIS PROJECT
 It is compact in size
 It can be move
 No electrical power consumption
 It can be utilized at our work shop
 It is simple in construction
 Low cost
 Less weight and easy to handle
 It reduces the man power
 It is simple in operation..

53. RESULT AND DISCUSSION

54. RESULT AND DISCUSSION
The various type of pumps are used for pumping the water
from a sump to tank. This is also one of the hand operated pump
which is now operated through the cycle pedal .The operation and
mechanism of this unit and its function have been studied.
At the end, the machine is assembled.
This machine is more advantages of other types of hand pump
since it has more easier to operate comfortable seating
arrangement and good exercise to our body and also less time
consumption, easy handling etc.

55. COST ESTIMATION

56. COST ESTIMATION
1. suction pipe line and connector--------------------200.00
2. Hand pump unit 2800.00
3. Crank rod 600.00
4.M.S. Fabricated BASE unit 1600.00
5. PEDAL & SEAT UNIT 600.00
6. transport cost 200.00
TOTAL COST 6000.00

57. CONCLUSION
CONCLUSION
We make this project entirely different from other projects. Since
concepts involved in our project is entirely different that a single unit is used
to various purposes, which is not developed by any of other team members.

58. By doing this project we gained the knowledge of fabrication work
and how the welding is doing and material selection for particular
components etc.,
It is concluded that any fabrication work can be done with the help of
welding.
We have successfully completed the project work on using welding
work at our Institute.
Once again we express our sincere thanks to our staff members.

59. BIBLIOGRAPHY
BIBLIOGRAPHY
1. WORKSHOP TECHNOLOGY -HAJRA CHOWDRY

60. 2. PRODUCTION TECHNOLOGY -R.S. KHURMI
3. MACHINE SHOP TECHNOLOGY -S.S.MANIAN
4. JIG AND FIXTURE DESIGN - R.K.JAIN
5.FLUID POWER BY -E.SUNDRAMOORTHY
PHOTO VIEW

61. PHOTO VIEW